Technical part about sewage pipe systems - FRANK GmbH · Technical part about sewage pipe systems. About this catalogue This catalogue provides an overview of the applications and

Sew

age

and

envi

ronm

enta

l te

chn

olgy

Technical part aboutsewage pipe systems

About this catalogue

This catalogue provides an overview of the applications and installation options available with our quality pipe systems. The data

and recommendations in this document are based on recognised technical standards and our extensive experience in the field

of plastic pipe systems. The catalogue thus serves as a comprehensive reference handbook that assists you in your planning and

installation tasks.

Copyright:

All rights reserved. Reproduction of this catalogue, by whatever means, in full or in part, is only permitted with the prior written

consent of FRANK GmbH.

Although every effort has been made to provide complete and accurate information, FRANK GmbH does not accept any liability

whatsoever arising from any errors or omissions.

© FRANK GmbH Status 12/2013 Subject to change without prior notice

Technical expert advice

Our technical expert advice service focuses on the application of our products, based on best technical practice. All information

provided is to our best knowledge and does not constitute a binding guarantee of specific properties. Our recommendations do

not absolve you from the obligation to examine the suitability of the products for your specific purposes.

Fig. 1 - Spiral pipe production at FRANK & KRAH Wickelrohr GmbH

1Sewage pipe systems | December 2013

Table of contents

1. System information

1.1 Introduction ...............................................................5

1.2 PKS® sewage pipe system ..................................6

1.3 TSC sewage pipe system ......................................7

1.4 Sureline® sewage pipe system ............................8

1.5 PKS® Secutec sewage pipe system ...................9

1.6 Plastic pipe production ......................................... 10

1.7 Spiral pipe profile types ..........................................11

1.8 Flexible sewage pipe system

and stress loads .................................................... 12

1.9 Commercial advantages of plastic pipes ......... 13

2. Identification

2.1 Spiral pipes (DIN 16961 / DIN EN 13476) ............ 16

2.2 Pressure pipes (DIN 8074/75), pipes

with high crack resistance (PAS 1075) .............. 17

2.3 Fittings (DIN 16963) .............................................. 17

3. Quality assurance

3.1 General information .............................................. 18

3.2 Internal quality monitoring ................................... 19

3.3 External testing complementing the

internal quality assurance system ...................... 21

3.4 External quality testing ........................................ 24

3.5 QM system according to DIN EN ISO 9001 ..... 25

3.6 Factory/inspection certificates according

to DIN EN 10204 .................................................. 26

4. Moulding material

4.1 Polyethylene ...........................................................27

4.2 Polypropylene ...................................................... 29

4.3 Material properties .............................................. 30

5. Resistance to pressure and wear

5.1 Creep rupture curves - DIN 8075

PE 100 pipes .......................................................... 31

5.2 Creep rupture curves - DIN 8078

PP-R pipes ............................................................ 32

5.3 Abrasion resistance ............................................. 33

5.4 Resistance to high pressure cleaning .............. 35

6. Calculations

6.1 Determination of pipe cross-section for

gravity pipelines.................................................... 36

6.2 Stress resulting from insulation and

groundwater above pipe level ............................37

6.3 Calculations for underground sewage

pipes according to ATV-DVWK-A 127 .............. 38

6.4 Calculation of pipe wall thickness smin

based on operating pressure ........................... 40

6.5 Stress due to external overpressure

(buckling pressure) .............................................. 40

6.6 Creep rupture curves for PE 100

according to DVS 2205-1 .................................... 41

6.7 Calculation of elongation .................................... 42

6.8 Fixed points in exposed pipelines ..................... 43

6.9 References ........................................................... 43

7. Static strength questionnaire/manhole data

sheet

7.1 Static load questionnaire for the calculation

of under-ground sewage pipes according

to ATV-DVWK-A 127 ............................................ 44

7.2 Static load questionnaire for the calculation

of under-ground plastic manholes following

ATV-DVWK-A 127 ................................................ 46

7.3 Explanations re. questionnaires ........................ 48

7.4 Manhole data sheet ............................................ 50

2 December 2013 | Sewage pipe systems

Table of contents

8. Installation

8.1 General installation guidelines ............................. 51

8.2 Trench installation - PKS®/TSC pipes ............... 53

8.3 Trenchless installation ......................................... 56

8.4 Leakage test for gravity pipelines ..................... 58

8.5 Leakage test for pressure pipelines ................. 59

9. Connecting techniques

9.1 Overview of welding methods ........................... 60

9.2 Electrofusion welding of DIN 16961 /

DIN EN 13476 spiral pipes ................................... 61

9.3 Electrofusion welding following DVS 2207-1,

process description for DIN 16961 /

DIN EN 13476 profiled sewage pipes ............... 62

9.4 Extrusion welding according to

DVS 2207-4, process description for

DIN 16961 / DIN EN 13476 profiled

sewage pipes ....................................................... 64

9.5 Electrofusion welding according to

DVS 2207-1, process description

for extruded DIN 8074/8075 pipes .................. 65

9.6 Butt welding according to DVS 2207-1,

process description for extruded

DIN 8074/8075 pipes ...........................................67

9.7 House connections ............................................. 69

9.8 Plug-in connections - TSC pipe system ...........70

9.9 Detachable connections -

flange connections ............................................... 71

10. Manholes and special constructions

10.1 PKS® manholes ....................................................72

10.2 PKS® standard manhole - inspection

manhole .................................................................73

10.3 PKS® standard manhole - tangential

manhole ................................................................74

10.4 PKS® storm water system .................................75

10.5 PKS® special constructions - examples ..........77

11. Project reports

11.1 Neckar culvert: Large-diameter spiral pipes

made in polyethylene ..........................................79

11.2 Steinhäule wastewater treatment plant .......... 82

11.3 Sureline® pipes for Hamburg pressure

drainage system .................................................. 85

11.4 Storm water channel Sportlaan,

Netherlands .......................................................... 86

12. Standards and regulations ..................... 87

13. Index ....................................................... 91


FRANK GmbH has been involved since 1965 in the production and installation of plastic pipe systems. The company has been one

of the main contributors to the development of modern PE and PP pipes for all types of applications.

Fig. 2 - Headquarters of FRANK GmbH at Mörfelden, Germany

Plastic pipe systems from FRANK GmbH are used for a wide

range of applications:

� Sewage pipe systems

� Storm water systems

� Ventilation ducts

� Landfill gas extraction and drainage systems

� Waste incineration

� Process pipes for aggressive substances

� Double containment pipes and vacuum systems

� Pressure drainage

� Power plants

� Biogas systems

� Drainage/perforated pipes

� Special pipes for installation without sand-embeding

For all applications, the pipes as well as the connection technol-

ogy and the fittings need to be tested and certified in advance.

FRANK GmbH was involved as a competent partner in all these

tasks from the very beginning.

Based on this experience, FRANK GmbH has been able to

develop a comprehensive range of products for a variety of

applications.

FRANK GmbH also offers welding technology for pipeline sys-

tems, connecting parts for manholes, connectors to other pipe

types and a complete range of fittings.

FRANK GmbH is your competent partner for plastic pipe sys-

tems.

To find out more, simply give us a call!

Your FRANK GmbH team

Phone: +49 6105 / 4085 - 0 Fax: +49 6105 / 4085 - 249 E-mail: [email protected]

Internet: www.frank-gmbh.de

Sewage CataloguePlastic pipe systems for sewage


For many decades, sewage systems consisted mainly of rigid pipe structures with socket connections that are prone to damage.

Excessive stress on rigid pipes can cause cracks or fragmentation of the pipe material, resulting in infiltration of ground water and

exfiltration of contaminated wastewater into the environment. For more than 40 years, RANK GmbH has been using plastic pipe

systems in a range of high-demand applications. Pipes made from flexible materials with tight, welded socket connections have

many advantages over rigid, push-fit pipe systems. The experience of the last decades has lead to the development of the PKS®

profiled sewage pipe system made in PE 100. The PKS® system allows for uniform, permanently tight sewage systems with pipes

of all conventional dimensions. The installation of storm water storage sewers, rain water tanks, landfill manholes, perforated pipes

and leachate reservoirs made from PE 100 pipes is a technically advanced yet affordable solution. The components can be made

to measure and fitted at the factory. This allows for fast installation on site, so that construction costs can be minimised.

Polyethylene and polypropylene

Polyethylene (PE) and polypropylene (PP) are thermoplastic materials with a low specific weight. They are very easy to process,

weld and form. Both materials are also resistant to aggressive media. Thanks to their molecular composition of carbon and hydro-

gen, they are 100% recyclable and thus environmentally friendly.

Polyethylene (PE) is character-

ised by low permeation, good

UV resistance (carbon black

stabilised), excellent chemical

resistance and physiological

safety. PE is the ideal material for

use in sewage systems in build-

ings and underground installa-

tions. It has also been used for

many decades in drinking water

systems and for the transport of

Fig. 3 - PKS® sewage pipe made in PE 100

Fig. 4 - Ventilation shaft made in PP-R

Polypropylene (PP) has a

higher heat distortion resist-

ance than most other ther-

moplastics. It offers great

mechanical strength, ex-

cellent chemical resistance

and physiological safety. PP

is widely used in the chemi-

cal industry, where high

temperature resistance is

a must.

chemicals and gases (e.g. natural gas). For all these applications,

high-grade PE 100 is the material of choice. FRANK GmbH has

been using PE 100 of the third generation for many years in its

components and pipes as standard.

Table 1 - Available dimensions for FRANK plastic pipe systems

System MaterialDimension

300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1800 2000 2300 2400 2700 3000 3500

PKS® sewage pipe PE 100* √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √

TSC-Pipe PE 100/PP √ √ √ √ √ √ √ √ √ √ √ √ √ √

PKS® Secutec pipe PE 100* √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √

PKS® under-ground ventila-tion pipe

PE 100* √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √

System Material SDR classOutside diameter d

160 180 200 225 250 280 315 355 400

Sureline pipe PE 100 RC SDR 11, SDR 17 √ √ √ √ √ √ √ √ √

SURE INSPECT RC PE 100 RC SDR 26 √ √ √ √ √ √ √ √ √

* option/available in PP or PE on request


1.1 Introduction



Fig. 5 - PKS® pipe welding zone

Fig. 6 - Pipe stock at Wölfersheim site

+ -

Spigot end

Socket equipped with electrofusion wire

Homogeneous welding zone

1.2 PKS® sewage pipe system

PKS® profiled sewage pipe system

The PKS® profiled sewage pipe system consists of light-weight,

dimensionally stable profiled pipes conforming to DIN EN 13476,

part 2 and 3 in sizes DN 300 to DN 3500, plus associated fit-

tings, manholes and connection parts such as house connec-

tion saddles for new buildings. PKS® sewage pipes are profiled

on the outside and feature a white lining for easy inspection. All

components are made from durable PE 100. Alternatively, the

pipes and fittings are available in PP-R (polypropylene), which

might be required for sewage pipelines that might withstand

high temperatures.

For smaller diameters (DN 150 to DN 300), we offer co-extruded

PE solid wall pipes according to DIN 8074/8075 with separate

electrofusion fittings. From DN 300, we offer pipes equipped

with an integrated socket and electrofusion wire at one end,

for on-site electrofusion welding (up to DN 2400). Pipes larger

than DN 2400 are ready for electrofusion welding according to

DVS 2207-4.

Advantages of PKS® pipes

� Light weight for easy handling

� Strong, permanently tight and uniform connection pro-

duced by electrofusion welding

� Electrofusion welds can be produced quickly and easily

� Electrofusion welded connections for DN 300 to DN

2400,

extrusion welding possible for sizes 300 to 3500

� Made for easy pipe welding under site conditions

� Flexible pipe material ensures permanently tight pipelines

even in the event of subsequent ground settlement

� Easy inspection thanks to bright inside lining

� Anti-adhesive surface provides excellent resistance to

abrasion and chemicals

� Expected service life: minimum 100 years

� Recyclable

Applications of PKS® pipes

� Ideal for all conventional and heavy-duty sewage and

manhole systems

� Storm water pipes, rain water tanks

� Pump shafts and landfill manholes

� Perforated pipes and leachate reservoirs

All pipe, manhole and fitting components are specifically de-

signed for use in sewage systems and underground installa-

tions. Our PKS® sewage pipes are high-quality products made in

modern spiral pipe production plants, where we use advanced

technology such as co-extrusion.

As polyethylene is a flexible material, short-term overloads of the

pipe system can normally be compensated without any lasting

effect. The components can be made to measure and fitted at

the factory. This ensures short installation times on site.

For the development of the profiled sewage pipe system, we

aimed at combining the advantages of profiled PE 100 pipes

with tight, uniform pipe connections, in order to allow for easy

installation. The electrofusion socket of our PKS® sewage pipe

systems from DN 300 to DN 2400 and our advanced spiral pipe

production technology allow for the installation of permanently

tight, durable and thus economically viable pipelines systems.


Fig. 7 - TSC pipe

TSC-Pipe - Twin Seal Connection-Pipe

For the drainage of surface and rain water, we offer a pipe sys-

tem with push-in connections. The pipes are available in polyeth-

ylene or polypropylene. Both materials are flexible so that TSC

pipes can be deformed to a certain degree without breaking.

This means that they can withstand considerable loads without

damage. The integrated, non-shifting and certified double seal-

ing technology prevents infiltration as well as exfiltration at the

joints, even under extreme loads.

TSC includes all components that are required for gravity pipe-

lines. In addition, we offer a complete range of fittings such as

branch sections, bends, slope drainage fittings, manholes, etc.

specially adapted for pipe systems.

Thanks to the light weight of the pipes and the push-fit connec-

tions, installation is quick and cost-effective. The pipes are black

on the outside to ensure permanent UV resistance, while the

grey co-extruded inner lining allows for easy camera inspec-

tion. The pipes are however also available with a black or grey

inner surface.

TSC-Pipe come in sizes DN 600 to DN 1200 and with a grey

inner lining as standard. Other options are available on request.


1.3 TSC sewage pipe system

Advantages of TSC-Pipe

� Easy to install, cost-effective and environmentally friendly

� Sturdy and durable

� Tight (exceeding DIN 4060 requirements) thanks to non-

shifting double sealing system

� Strong pipe of low weight, thanks to profiled pipe wall

according to DIN 16961

� Resistant against aggressive media and corrosion by

contaminations or bacteria, with anti-adhesion surface

that prevents deposits

� Abrasion and impact proof, resistant to UV light

� Excellent hydraulic performance due to smooth inner

surface finish (k < 0.05 mm)

� Easy inspection thanks to bright inside lining


� Recyclable

Applications of TSC-Pipe

� Drainage of surface and rain water

� Drainage of wastewater

� Gravity pipeline systems

� Culverts


Fig. 8 - Sureline® pipes


1.4 Sureline® sewage pipe system

Sureline® - optimised safety

Sureline® pipes are co-extruded solid wall pipes made from

high-quality PE-100-RC (RC = resistance to crack). Thanks to

the co-extrusion production process, Sureline® pipe are of excel-

lent, uniform quality across the entire wall thickness. PE 100-RC

exceeds the test requirements laid down in PAS 1075, such as

FNCT and point load test according to Hessel. Thanks to the use

of top-quality, non-crosslinked plastic, FRANK Sureline® pipes

provide excellent safety as they are resistant to point loads, crack

initiation, slow crack propagation and external impact.

High-quality pipe designed for cost-effective in-stallation

Due to their excellent properties, polyethylene pipes are be-

coming the preferred substitute for more traditional materials

such as cast iron and ceramics. This is not least due to the ever

more stringent statutory requirements that force operators of

pipeline systems to fix leaks and problems as quickly as pos-

sible. In many cases, existing metal pipelines are repaired with

PE pipes. As trenchless installation methods such as relining,

burst lining, ploughing or horizontal hydraulic drilling are extremely

cost-efficient, they have also become very popular for the instal-

lation of new pipes.

Advantages of Sureline® pipes

� Sureline® pipes are resistance to

- damage to surface (grooves) caused during trans-

port or installation

- point loads from rocks and stones

- Stress in pipe wall due to deformation (ground set-

tlement, dips in trench)

� Easy handling thanks to low weight: one DN 150 section

(d 160, SDR 17; length 6 m) weighs for example only

approx. 27 kg (ductile cast pipe DN 150: weight approx.

171 kg) and can be easily handled and moved on site by

one or two workers

� Available in sizes d 160 to d 400

� High-strength connections (electrofusion or butt welded)

� Reliable connections that remain tight even under ex-

treme conditions (e.g. temperature)

� Permanently tight pipelines thanks to flexible material (no

leakage even with subsequent settlement)

� Unrivalled resistance to abrasion and chemicals


� Recyclable

� Compatible with other commonly used PE pipes and

fittings

Sureline® pipes can be used for a number of installation methods

� Installation without sand-embedding

� Ploughing in of pipe

� Milling

� Relining of existing pipelines (long pipe relining)

� Burst lining

� Installation with drilling rocket

� Horizontal hydraulic drilling



1.5 PKS® Secutec sewage pipe system

PKS® Secutec - pipe system designed for monitor-ing

Installations such as drinking water supply systems and chemical

pipelines through groundwater protection zones require per-

manent monitoring. For this purpose, entire pipelines systems

must be tested by vacuum or permanent overpressure. Using

the defined hollow space method, PKS® Secutec pipes allow

for the continuous monitoring of the entire pipeline system. In

underground pipelines, it is possible to include manholes in the

monitored system (see also chapter 10, "Manhole construc-

tions").

The system can be monitored by means of an approved leak-

age detector, a mobile testing unit or a leakage check system

accessible from the operating room. Monitoring can extend

across the entire pipeline system or to isolated sections only.

Fig. 9 - Joining methods available with PKS® Secutec

Fig. 10 - PKS® Secutec sewage pipe

PKS® Secutec pipes are designed for joining by electrofusion

welding and come with an integrated electrofusion socket. The

monitoring area is produced by means of an additional extrusion

weld at the inside of the pipe, This section is connected to the

monitoring area of the adjoining pipe. Alternatively, it is possible

to join the pipes by means of an inner and an outer extrusion

weld, doing away with electrofusion welding. PKS® Secutec

pipes can also be joined by butt welding. All joining methods

guarantee homogenous and permanently tight connections of

the PKS® Secutec pipes.

The PKS® Secutec system is DIBt-approved and available in

diameters from DN 300 to DN 3500. The core wall thickness is

defined according to the project-specific requirements and with

regard to special customer requests.

Advantages of PKS® Secutec pipes

� DIBt approval for pipe system and welding method

� Excellent safety thanks to double-wall structure and

integrated monitoring system

� Pressure/leakage monitoring

� Simultaneous butt welding of inside and outside pipe.

� Available in DN 300 to DN 3500

� Excellent chemical resistance

� Easy handling and installation thanks to low weight

� Unrivalled resistance to abrasion and chemicals


� Recyclable

Applications

� Sewage pipelines through groundwater protection

zones

� Underground pipelines for water polluting substances

� Leachate drain lines in landfills

� Process lines for hazardous chemicals

� Other pipelines that require special leakage monitoring

Monitoring/testing area

1) PKS electronfusion socket weld

2) Heat element butt welding

Monitoring/testing area

Heat element butt welding for PKS plus (smooth)

Electrofusion welding (PKS electrofusion socket)

extrusion welding


DIN 16961 / DIN EN 13476 spiral pipes

The pipes are produced by means of the winding method as

specified in DIN 16961 / DIN EN 13476. The homogeneous,

thermoplastic band (profiled or solid form) is thereby wound

around a steel mandrel and connected by overlapping. The

profile pattern is aligned with the overlaps to ensure a uniform

wall thickness. The steel mandrel guarantees that the inside

diameter (DN) is the same in all sections, irrespective of the wall

thickness or stress applied to the pipe. This ensures that each

pipe consists of a homogeneous, high-density wall from the

socket to the spigot end.


1.6 Plastic pipe production

Fig. 11 - Production method for DIN 16961 / DIN EN 13476 spiral pipes

Fig. 12 - Production machine at FRANK & KRAH Wickelrohr GmbH

The discontinuous production

method allows for the manu-

facture of individual pipes with

special length and diameters.

The profile construction is

adjusted to suit the actual op-

erating conditions as specified

in the project documentation.

FRANK GmbH is therefore able

to produce sewage pipes that

meet your specific require-

ments and provides the neces-

sary safety tolerances.

DIN 8074/8075 pressure pipes

Pressure pipes according to DIN 8074/8075 are produced by

extrusion. With this continuous production method, the material

is extruded through a nozzle. With co-extrusion, two or more

melted plastics of the same type are mixed together before they

leave the profile nozzle.

Fig. 13 - Production method for DIN 8074/8075 pressure pipes

Sewage pipes for underground installation are produced with

special regard to the necessary long-term ring stiffness. In PKS®

/TSC- and PKS® Secutec sewage pipes, this is achieved by

choosing a suitable profile construction. We are thus in a posi-

tion to manufacture light-weight sewage pipes that offer high

long-term ring stiffness.

Fig. 14 - Extrusion plant for pressure pipes at AGRU-FRANK GmbH

The material to be extruded/

co-extruded is melted and

homogenized in a heated

extruder. The process is aided

by internal friction. The ex-

truder produces the pressure

required for the proper extru-

sion of the plastic. After the

plastic has been pressed out

through the nozzle, the result-

ing continuous pipe section is

calibrated and cooled.

After cooling, the extruded pipe is cut to size.


PKS® solid wall profile type

The PKS® solid wall pipes can be produced with various wall

thicknesses and with a co-extruded light-coloured inside lining

according to the static strength specifications or the needs of

the customer. Thanks to the homogeneous structure of the pipe

wall and the smooth inside and outside surfaces, the solid wall

pipes are particularly suitable for the production of manholes,

bends and other similar installations. For upright tanks, we offer

solutions with a graduated wall thickness that conforms to the

relevant standards. Our products are available with a wall thick-

ness of up to 400 mm.

Solid wall pipes are available with standard or electrofusion

sockets and spigot ends as well as with smooth ends. Pipes

up to DN 2400 are connected by means of electrofusion weld-

ing. From DN 300 to DN 3500, extrusion welding can be used.

PKS® profile type PR, PRO (DN 300 to DN 3500)

The PKS® profiles of the PR type offer excellent ring stiffness

combined with extremely low pipe weights. The PR pipes are

mainly used for underground sewage systems up to size DN

3500. Where installation is difficult or pipes are exposed to ex-

treme loads, we recommend using pipes of the PKS® Pro profile.

With this pipe type, connections are made by electrofusion weld-

ing up to a nominal diameter of DN 2400. As an alternative to

electrofusion welding, pipes from DN 300 to DN 3500 can also

be joined by extrusion welding. The pipes come with integrated

sockets and spigot ends.

The PKS® system range also includes extruded PE 100 pipes

conforming to DIN 8074/75 in sizes from D 160 SDR 17/SDR 11

to D 400.

PKS® profile type PKS®plus, SQ (DN 300 to DN 3500)

PKS® profiles of the PKS®plus or SQ type offer particularly high

long-term ring stiffness, thanks to their compact profile struc-

ture with smooth and fully sealed outer surfaces. They are the

preferred option for systems that are exposed to exceptionally

high stress.

As the outside surface is smooth, this pipe type is particularly

suitable for the production of manholes and similar applications

in pipeline systems.

The PKS® pipes of this type can be produced according to

customer requirements regarding ring stiffness and core wall

thickness. Up to DN 2400, the individual pipe sections can be

joined by electrofusion welding. From DN 300 to DN 3500, ex-

trusion welding can be used, and pipes of this size come with

spigot ends and sockets as standard, similar to profile type PR.


1.7 Spiral pipe profile types

Fig. 15 - Top: solid wall profile; bottom: graduated solid wall profile

Fig. 16 - Top: PR profile; bottom: PRO profile

Fig. 17 - Top: PKSplus profile; bottom: SQ profile


Advantages of flexible sewage pipes

During their lifetime, underground pipes are exposed to various

and changing loads. In many areas, sewage pipes that were

installed nearly 100 years ago are still in use. During this period,

the traffic load increased dramatically due to the increase in mo-

tor traffic and urbanisation. Today's stress loads are thus much

higher than several decades ago. We can only guess what loads

newly installed sewage systems must withstand in 50 years time

from now. As sewage systems are to last for several decades,

it is important to choose pipes and fittings that will not fail under

increased stress.

Pipes made in traditional materials, which are still prevalent in

our sewage systems, are prone to cracking, fragmentation,

collapse and socket disconnection. Such damage is generally

due to settlement of the surrounding ground, which causes

excessive stress at the top of the pipe. Other causes of leak-

age are tree roots near house connections and socket joints.

Future-proof sewage systems must be made of pipes that are

not prone to such failures.

Moving with the force

We know from nature that the thin branches and leaves of a tree

are in constant motion when there is wind. At a closer look, we

can see that they move with the wind until its impact is minimised.

In other words, they move with the force. Would it not be per-

fect if such deformation under load could be incorporated into

sewage pipe systems? This is exactly what the PKS® system

does. Made from flexible polyethylene or polypropylene, the

pipes allow for a certain degree of deformation under load. As

a consequence, the stress load in the material is reduced. The

risk of overload and rupture is therefore minimised. As soon as

the load is reduced, the PKS® pipes return to their initial shape.

PKS® pipes thus introduce flexibility into the sewage system,

Making use of the load-bearing capacity of the surrounding soil

In contrast, rigid pipes made in stoneware or concrete are not

able to compensate for changing loads and are thus at all times

exposed to the full traffic load and weight of the soil cover. With

PKS® pipes, the loads are transferred to a wider area as the pipe

bends slightly. As the top of the pipe is lowered, the load con-

centration above the pipe is reduced. The desired deformation

shifts the flanges slightly outwards, which results in additional

bedding pressure so that the pipe is supported at both sides.

Thanks to the deformation of the PKS® pipe, a new equilibrium

of the forces acting on the pipe is achieved. The PKS® pipe

can thus withstand even heavy loads, despite its light-weight

construction.


1.8 Flexible sewage pipe system and stress loads

Fig. 18 - Flexible sewage pipe

Fig. 19 - Forces acting on flexible sewage pipe

Fig. 20 - PKS® sewage pipe


calculative interest on own capital

9%

other running and maintenance costs

25%

personnel costs13%

sewage tax8%

calculative amortisation

29%

effective intereston debt

16%

Fig. 21 - Cost analysis of German sewage system operators (Source: TU Darmstadt - Empirical study, 2006)

Fig. 22 - Frequency of common damage (source: empirical study by TU Darmstadt, 2006)

PE

concrete

stoneware

est

imate

d fre

quency

pipe

bur

stflo

w b

arrie

r disp

lace

men

tro

ot d

amag

es

dam

aged

con

nect

ion

corro

sion

mec

hanica

l abr

asion

crac

k gr

owth

defo

rmat

ion

untig

ht c

onne

ction

high

1.9 Commercial advantages of plastic pipes


Cost-efficient and sustainable solutions

According to the latest survey by the German Association for Water, Wastewater and Waste DWA, local authorities are facing

costs in the region of billions for the replacement of leaking and outdated sewage systems. As the public purse is empty, new

solutions must be found to reduce the running costs in the public sewage treatment sector. On the one hand, citizens want to

keep wastewater charges low, while operational safety of the system is of course a major priority.

A survey carried out by the Technical University Darmstadt in 2006 among German sewage system operators, the cost reduction

potential of high-quality sewage pipe systems made in PE was analysed. For the study, 83 operators of public sewage systems

were interviewed. This group serves 18% of the population in Germany. With over 56,600 kilometres of sewage pipelines, the

above operators look after nearly 12% of the German public sewage network.

The study revealed that the key cost factors for wastewater

system operators are network maintenance and repairs (approx.

25%) and depreciation (approx. 29%), see figure 21. By reducing

these costs, operators would be able to lower the wastewater

treatment charges.

The depreciation figures are mainly determined by the expected

service life of the fixed assets. Around 70 to 80% of funding

required for the installation of a wastewater treatment system

is spent on the sewage pipelines. By choosing a pipe material

that has a long service life, it is thus possible to significantly re-

duce the depreciation rates. Even if the initial installation would

be slightly more expensive, such advanced systems will reduce

the overall lifetime costs and thus the wastewater treatment

charges for customers.

Taking into account the overall investment, the actual material

costs for the pipe are a relatively small expense, so that the deci-

sion for or against a particular material should not be based on

its price, but rather on technical criteria. Of main concern here

are the service life of the pipe and the connections and other

quality properties as well as installation site conditions (see

figures 22 and 24).


Saving money by reducing repair costs

Sewage system operators see significant cost savings in the field of repairs, if the occurrence of relatively expensive damage

such as pipe fracture/collapse and defective connections (generally associated with extensive work in open trenches) could be

reduced. This can be achieved by proper installation of the pipes and the use of a pipe material that is appropriate for the job. By

using PE 100 pipes in sewage pipe networks, operators can save money, as the above expensive problems are less likely (see

figures 22, 23, 24).

0 1 2 3 4 5 6 7

untight connection

deformation

mechanical abrasion

corrosion

damaged connection

root damages

displacement

flow barrier

pipe burst

cost estimation

very expensive

crack growth

Fig. 23 - Estimated costs for the repair of certain types of damage (source: empirical study by TU Darmstadt, 2006)

When comparing the types of damage (figures 22 and 24) with

the associated repair costs (figure 23), it becomes obvious that

PE has significant advantages over rigid pipe material, especially

in relation to the most costly repairs.

The only exception here is deformation. Flexible pipes show a

deformation damage rate of 0.7 per kilometre of sewage line.

It remains however unclear whether such deformation should

actually be considered a defect. According to ATV-DVWK-A 127,

deformation is permitted to a certain degree and actually taken

into account for the static calculations of flexible pipe systems.

Such deformation does not have an adverse effect on the

function of the pipe system. In addition, extreme deformation

is normally not caused by the material but by poor installation or

significant overloads, which can be eliminated by proper plan-

ning and engineering.0 2 4 6 8 10 12 14 16

surface damage

deformation

infiltration

displacement

flow barrier

rate of damages (damages per kilometer)

flexible pipe material

rigid pipe material

pipe burst/collapse

damaged connection

protuberant house connection

Fig. 24 - Occurrence of damage in pipe systems made from rigid and flexible materials (source: empirical study by TU Darmstadt, 2006)




Reasons behind increased use of plastic pipes in sewage networks

For the study by TU Darmstadt, sewage network operators were asked about the criteria they consider when choosing a specific

pipe material. The public company managers were asked to state the five pipe properties they consider most important (figure 25).

A long service life of the pipe was mentioned by 72 of the surveyed companies, putting it to the top of the table. Nearly 90% con-

sidered a long service life the main requirement to be met by a pipe material. More than 40% thought that resistance to corrosion,

tightness of the connections, low operating and repair costs as well as a minimum risk of installation errors were important factors.

These properties actually have a significant effect on depreciation and operating expenses (see figure 21).

46%

4%

7%

9%

14%

15%

21%

36%

40%

41%

43%

51%

89%

0 10 20 30 40 50 60 70 80

frequency of nominations (N = 81)

long life-time

other features

long-term ring stiffness

low material costs

high resistance to corrosion

low installation costs

good availability of complete systems

break-proof

qualified for high pressure cleaning

low risk of installation errors

low running and maintenance costs

high tightness on connections

high resistance to corrosion

Fig. 25 - Rating of pipe properties by sewage system operators (source: empirical study by TU Darmstadt, 2006)

When purchasing a sewage pipe system made in PE 100, system operators are looking for a solution that requires only minimum

maintenance, remains operational for a period of 100 years or more and can be repaired and maintained at low costs. As sewage

pipe systems made in PE are welded throughout, irrespective of the pipe diameter, they are exceptionally tight and durable. In

contrast, rigid pipes made from conventional materials tend to be prone to leakage at the push-fit connections, which can lead

to significant repair costs.

When comparing flexible and rigid pipe materials with regard to pipe break/collapse, which has been identified as the most frequent

cause of costly repairs, it becomes clear that flexible pipes made in a material such as PE 100 are significantly less likely to break or

collapse. Based on their practical experience, sewage system operators estimate that the overall maintenance and repair costs

for PE sewage pipes are clearly below 10% of the overall costs. According to DIN 8074/8075, the expected service life of PE pipes

is at least 100 years, which means that indirect costs arising from depreciation are also significantly reduced. For operators who

are looking for an economically viable and lasting solution when upgrading their sewage system, the only obvious future-proof

option are pipes made in polyethylene.




2. Identification

Standard identification

The standard identification mark is produced during production by means of an embossing punch that is adapted to suit the pipe

diameter. It contains all relevant pipe specifications. For spiral pipes, the standard identification mark allows for complete traceability

of the batch and contains the following details:

2.1 Spiral pipes (DIN 16961 / DIN EN 13476)

� DIN 16961 / DIN EN 13476

� Manufacturer

� Type of profile (e.g. PR 75-17.4)

� Material class

� Dimensions (inside diameter)

� MFR group

� Date of manufacture

� Pipe series

� Consecutive pipe number

Fig. 26 - Production machine of FRANK & KRAH Wickelrohr GmbH

Fig. 27 - Pipe identification mark


Fig. 28 - Component traceability code

* barcode conforms to ISO/FDIS 1276-4 (November 2003)

The fittings are marked during production by means of special

inserts placed in the injection mould.

Each identification mark contains the following details:

� Manufacturer

� Abbreviation and classification of material

� Dimensions (outside diameter x wall thickness)

� ISO or SDR code

� Factory serial number (indicating year of manufacture)

The electrofusion fittings and other fittings with long welding

ends from D 110 also bear the welding code and the component

traceability code. This barcode (128 type C*) contains all details

of the fitting batch.

Fig. 29 - Identification mark on extruded sewage pipe

2. Identification

During production, the pipes are marked at distances of one

metre by means of embossing.

The identification mark indicates the pipe material. Each standard

mark contains the following details:

� Manufacturer

� Material code

� Dimensions (outside diameter x wall thickness)

� Pipe series (ISO , SDR code)

� Rated pressure (PN ...)

� Year of manufacture

� Applied standard

� Factory batch code

The marks for all pressure rating classes are applied in a colour

that differs from that of the pipe material, whereby the size of

the writing varies, depending on the pipe diameter.

2.2 Pressure pipes (DIN 8074/75), pipes with high crack resistance (PAS 1075)

Fig. 30 - DA 160 and DA 560 electrofusion socket

2.3 Fittings (DIN 16963)



Raw materials

Prior to the launch of a new product, all tests laid down in the

requirement specifications are carried out and documented.

Before the materials are used in serial production, a trial manu-

facturing run is completed and the pipes and fittings undergo

long-term tests. If our factory standards and criteria, which are

significantly more stringent that the standard requirements, are

met, we enter into a supply quality agreements with the raw

material suppliers that are binding for all future deliveries.

A material is only approved for serial production after an exten-

sive production trial phase has been completed successfully. In

the meantime, a number of material tests are performed by an

independent external lab in order to verify the results.

All incoming raw materials and semi-finished products are care-

fully inspected before they are released for use in production.

In the inspection process, the suitability of the goods for the

intended purpose is verified.

Products

Underground pipes for the transport of wastewater and sew-

age need to withstand media that tend to contain ever more

aggressive components. At the same time, the requirements

regarding the protection of the environment have become much

more stringent than in the past. This means that modern pipe

systems must meet extremely high quality standards as regards

their production, development and installation.

As part of our internal quality assurance system, all in-process

tests and inspections that are required by the relevant standards

are performed at regular intervals by qualified staff. Our laborato-

ry technicians take samples from each production batch, which

are used for more detailed physical tests. All these procedures

are performed according to the relevant product standards.

The following routine tests are carried out as part of our internal

quality assurance system:

� Incoming inspection of raw material batches Melt flow index Homogeneity of material Moisture content Material density Colour

� In-process control Colour Identification Surface properties Delivery condition X-ray examination (injection-moulded fittings) Dimensions

� Quality inspection of extruded solid wall pipes Dimensions Melt flow index Homogeneity of material Behaviour after heat treatment Internal pressure creep test

� Quality inspection of profiled sewage pipes Dimensions Melt flow index Ring stiffness Tensile strength of pipe connections Tensile strength of pipe between profiles

� Pre-delivery inspection Packaging Delivery condition Dimensions Electrofusion wire resistance

3.1 General information

Fig. 31 - Ultrasonic measuring device

Fig. 32 - Pendulum impact tester



3.2 Internal quality monitoring

MFR - melt flow rate according to ISO 1133

The viscosity of the various polyethylene melts is determined by

means of a MFR meter. This parameter is determined during the

incoming inspection and at regular intervals during the produc-

tion process. For PE, the melt flow rate is normally determined

at a temperature of 190° C and a load of 5 kg (MFR 190/5).

Density according to DIN EN ISO 1183

The density of plastics is a parameter that is easy to measure and

that allows for the detection of physical and chemical changes in

the material. The density determines the mechanical properties

of the material and is therefore measured during the incoming

inspection.

Tensile strength test according to ISO 6259

Tensile tests can be used to determine a number of mechanical

properties of a material. The most common parameters are the

yield strength, the failure stress and the elongation at break.

Moisture content

During the incoming inspection, the moisture content (volatile

component) of each raw material batch is determined by means

of an infra-red measuring device. This is done according to the

internal inspection instruction. The results of the upstream drying

unit are taken into account for the production.

Fig. 33 - Melt flow rate

Fig. 34 - Measurement of moisture

Fig. 35 - Material density

Fig. 36 - Tensile strength testing system



Internal pressure creep tests according to DIN 8075

To determine the expected service life of a pipe, each batch

undergoes an internal pressure creep test. For each material

class, the testing parameters laid down in the applicable regula-

tions and standards are used.

3.2 Internal quality monitoring

Ultrasonic testing of wall thickness according to factory standard

As part of the internal quality assurance system, the wall thick-

ness of the profiled sewage pipe is measured by means of

ultrasound. This test is performed in order to ensure that the

pipe has the minimum wall thickness at all points between and

below the profiles.

Tensile test of profile according to DIN EN 1979

This test determines the short-term tensile strength of an overlap

seam and is especially suitable for thermoplastic spiral pipes with

profile walls. A test sample cut perpendicularly from the over-

lap seam is placed in the tensile testing device. The force in N

(Newton) at which the seam breaks corresponds to the tensile

strength of the overlap seam.

Testing of SR ring stiffness (DIN 16961 / DIN EN 13476)

The constant load test is performed in order to verify the cal-

culated SR ring stiffness. In this process, a constant linear load

is placed on the top of the pipe.

Testing of SN ring stiffness (ISO 9969)

In the constant speed test, the spiral pipe to be tested is de-

formed vertically by 3 % (relative to its inside diameter). The de-

formation force required to achieve this is then used to calculate

the corresponding SN value of the pipe.

Fig. 37 - Internal pressure creep testing device Fig. 38 - SR/SN ring stiffness testing system

Fig. 39 - Ultrasonic examination Fig. 40 - Tensile testing machine



Introduction

Over long periods of stress and/or at high temperatures, even minute defects such as notches in the material can lead to brittle

failure of PE/PP pipes. This failure is due to slow crack propagation. In the past, a number of test methods have been developed

that are able to simulate brittle failure. Based on the relevant test results, a material can be improved to show high resilience against

slow crack propagation. The most common test methods used today are the notch test and the FNCT (full notch creep test).

Depending on the installation and operating conditions, pipelines can be exposed to extremely high stress. The resistance to the

various stress factors can be determined in the lab by means of accelerated test.

These tests take into account that pipes laid by alternative methods tend to become damaged when coming into contact with

stones, rock and similar hard material. While such damage normally affects only the surface of the pipe, they might be rather deep

(e.g. grooves) with sharp edges. This results in a stress concentration on top of the "normal" stress (e.g. internal pressure, traffic

load, settlement).

To guarantee safe operation of polyethylene pipes that are installed by means of alternative techniques, the pipes must meet

certain minimum requirements, in particular as regards creep resistance. For a definition of these properties, please refer to PAS

1075. This publicly available specification complements the existing standards and regulations. It describes the technical require-

ments and test procedures for pipe materials and pipe systems.

01.000

2.000

3.000

4.000

5.000

6.000

7.000

8.000

9.000

10.000

PE 63 PE 80 PE 100 Sureline®

rupture time of point load resistance [h]

2% aqueous solution of Arkopal N-100

temperature: 80 °C stress: 4 N/mm²

(PE 100 RC)

> 8.760 h

Point load test according to Hessel for extruded solid wall pipes (PA PLP 2.2-2 2004.05)

This test method has been approved by Deutsches Akkredit-

ierungssystem für Prüfwesen GmbH and essentially combines

an internal pressure test with an external point load test. The

test simulates the stress that might occur on a buried pipe that

rests on a pointed stone in the sand embedding (simulated in

the lab by a 10 mm punch).

The test is performed at an increased temperature (80°C) and

with a wetting agent (e.g. Arkopal N-100). The strength re-

quirements for point loads are based on the need for a pipe to

withstand such additional loads without showing stress cracks

with subsequent failure.

3.3 External testing complementing the internal quality assurance system

0

1.000

2.000

3.000

4.000

5.000

6.000

7.000

8.000

9.000

10.000

PE 100 (standard requirements)

PE 100 (standard)

Sureline®(PE 100 RC)

notch resistance [h]

notch depth: 20 %

temperature: 80 °C testing pressure: 9,2 bar

> 8.760 h

Notch test (DIN EN ISO 13479)

The notch test is performed to test extruded solid wall pipes. It

can best be described as a modified internal pressure creep test,

whereby the failure point is predefined by a notch (opening angle

60°, notch depth = 20 % of wall thickness). Four such notches

are produced at equal distances along the circumference of the

pipe. The test is performed at 80°C with 4.6 N/mm².

The minimum standard requirement for PE 100 pipes is > 500

h (DVGW GW 335-A2). For protective pipes, it is > 5000 h. The

latest test results are shown below:

Fig. 41 - Point load resistance Fig. 42 - Notch resistance


*High-density polyethylene (PE-HD) pipes are only suitable for

use as cable duct pipes. There are therefore no specific test

criteria for long-term internal pressure creep testing. Given

the general approach of only using high-quality materials for

sewage pipes, raw materials labelled simply "PE-HD" are never

deemed suitable.

Test results at 80°C MPa in water

Material without wetting agent

with Arkopal 100-N wetting agent

PE-HD* n/a

PE 80 600 h ≥ 100 h

PE 100 1900 h ≥ 300 h

Table 2 - FNCT minimum requirements according to DIBt

FNCT (full notch creep test) according to DIN EN 12814-3; DVS 2203-4 Supplement 2

For this test, rods (i.e. specimens cut in radial direction from the

pipe wall) are prepared with a circumferential notch. These rods

are then tensile-tested with wetting agents (e.g. Arkopal N-100)

at an increased temperature (80 or 95°C). With this testing

method, clearly differentiated results can be achieved for the

various moulding materials with relatively short testing times.

The stronger the material, the longer it takes to break them.

1

10

100

1.000

10.000

PE 63 PE 80 PE 100 Sureline ®

FNCT rupture time [h]

2% aqueous solution of Arkopal N-100

temperature: 80 °C stress: 4 N/mm²

PE 100PE 80PE 63

F

F

(PE 100 RC)

> 8.760 h

FNCTFull notch creep test

Long-term tensile test

Test specimen: (100 x 10 x 10) mmNotch: 1.6 mm; circumferential

Test conditions for PEStress = 4 MPaTemperature = 80 °C2 % Arkopal N-100



Fig. 43 - FNCT

Fig. 44 - Full notch creep test results of different materials

Special properties of PE 100-RC

Through optimisation of the manufacturing process of poly-

ethylene materials by copolymerisation with suitable alpha

olefins, producers have been able to come up with PE-100

raw materials that offer exceptionally high creep resistance.

These PE-100 compounds are generally known as PE 100-RC

and are mentioned in PAS 1075 in connection with the use of

alternative installation techniques. "RC" stands for "resistance

to crack", as FRANK Sureline® pipes are made from this mate-

rial and are therefore particularly suitable for conventional laying

techniques according to PAS 1075. The PKS® sewage pipe with

light-coloured inside surface made in F100+ is also classified as

a PE-100-RC product (DIBt certificate Z40.25-399). The ad-

vantages of a light-coloured inside surface that allows for easy

inspection made in a high-quality material are obvious: long

service life, high abrasion resistance and minimised surface

roughness (Kb) or exactly what is required for the transport of

sewage and wastewater.

According to PAS 1075, each batch must undergo a full notch

creep test in order to be classified as a PE 100-RC material. For

this purpose, FRANK has commissioned Hessel Ingenieurtechnik

GmbH to perform accelerated tests at increased temperatures.

Results of external tests

The tests carried out by independent testing institutes (notch

test, internal pressure creep test, point load test) confirm the

excellent physical and chemical properties of the moulding

material used by FRANK. Of special importance here are the

properties of PE 100-RC, as this material makes the Sureline

pipes particularly suitable for laying by means of alternative

techniques, as is documented in PAS 1075.


Tensile testing of weld

To verify the safety of electrofusion welds, FRANK commissions

an independent lab for the long-term tensile testing of electrofu-

sion wire connections. The load is thereby applied at right angles

to the joining plane. These tests are performed according to DVS

standard 2203-4, Supplement 1 at 80°C and with a test load of

3.0 N/mm2 (standard requirement: 2.0 N/mm²).



Pipe

SocketElectrofusion wire plane

Joining plane

Conclusions

Given the failure pattern along all the electrofusion wire plane

in the electrofusion socket welds, it is reasonable to conclude

that the strength of the joining plane is greater than that of the

electrofusion wire plane.

The durability of these connections is thus determined by the

notch cavities around the electrofusion wires and the notch

sensitivity of the material of the socket during machining.

In contrast to electrofusion welds in gas and water pipes made

in conventional PE, PKS® welds can withstand forces that are

higher by a factor of approx. 3.

These tests have been performed for all available pipe dimen-

sions, whereby failures only occurred in the plane of the elec-

trofusion wire. Welds in PKS® pipes reached test times of up to

500 hours. This means that these welding connections meet

the test requirements, and that welding is a suitable method to

achieve lasting tightness even under long-term stress.

Fig. 45 - Tensile test in electrofusion wire plane

Fig. 46 - Hessel certificate - electrofusion weld testing

Fig. 47 - Specimen with tensile test failure pattern


Material/ product Pipes Fittings

PE Z-40.23-231 Z-40.23.232

PP Z-40.23.233 Z-40.23.234

F100+ Z-40.25.399

PE spiral pipe Z-40.26.359

PP spiral pipe Z-40.26.343

Table 3 - DIBt approval numbers


3.4 External quality testing

Our products are tested regularly according to the relevant

standards and certificates by approved test laboratories with

which we have entered into long-term quality assessment

contracts.

The following specialist test labs are currently involved in the

external testing of our production of pressure pipes and PKS®

pipes:

� State Material Testing Institute, Darmstadt (MPA)

� Hessel Ingenieurtechnik GmbH, Rötgen

The high quality standard of our products is documented by a

number of approvals and certificates.

As a rule, we only process moulding materials that have been

approved by DIBt. Of special importance here are high oxidation

stability (OIT value) of the material and a high resistance to slow

crack propagation.

By applying test criteria that are more stringent that those laid

down in the relevant standards, and by performing tests that are

beyond the scope of the current regulations, we can guarantee

high system safety.

Our PE and PP products are DIBt-approved under the following

certificate numbers:

Fig. 48 - Hessel - continuous quality assessment contract

Fig. 49 - DIBt approval for PKS® Secutec and PE 100 spiral pipe



3.5 QM system according to DIN EN ISO 9001

For many years, all relevant procedures and processes at

FRANK GmbH are covered by a quality management system

according to DIN EN ISO 9001. The quality management system

is regularly audited by TÜV Rhineland and aims at meeting the

expectations of customers at every level.

It therefore does not only cover the quality of our products and

the further development of our product range, it also helps us

improve our customer services. Through regular staff training

and a number of continuous improvement measures, we are

taking all the necessary steps to further improve our delivery

performance and expertise in the field of plastic pipe systems.

Our high quality standards must of course also be met by our

suppliers. The operation of a quality management system ac-

cording to DIN EN ISO 9001 is only one of many requirements

that our supply partners must fulfil. Through the careful choice

of our suppliers and continuous supplier verification, we have

been able to establish long-term partnerships with a number of

reliable moulding material producers.

Our production plants are equipped with the latest technology.

Testing and measuring equipment that is directly integrated into

the manufacturing process ensure the consistent high qualify

of our pipes and fittings.

Fig. 50 - DIN EN ISO 9001 certificate



As each pipe and fitting is equipped with a serial number, it is

possible to trace it back to the original raw material batch. All

tests and inspections performed from the incoming inspection to

the pre-delivery check are documented in inspection certificates

according to DIN EN 10204.

These certificates are available on request from our QA depart-

ment.

Due to more than 40 years of experience in the manufacture of

semi-finished products made from polyolefins and our rigorous

internal quality assurance system, the quality of our products far

exceeds the relevant international minimum standards.

3.6 Inspection certificates according to DIN EN 10204

Fig. 51 - Inspection certificate from AGRU-FRANK GmbH Fig. 52 - Inspection certificate from FRANK & KRAH Wickelrohr GmbH


General properties of polyethylene

Thanks to the continuous develop-

ment of enhanced PE moulding

material over the last few years, the

quality of PE pipes and fittings has

been significantly improved.

Previously, polyethylene (PE) has

been classified according to its

density (PELD, PEMD, PEHD). To-

day, the materials are classified ac-

cording to ISO 9080 based on their

hydrostatic strength (PE 63, PE 80,

PE 100).

Moulding materials previously known as PEHD are no longer

relevant for technical applications and are now classified in PE 80.

In contrast to other thermoplastics, PE offers excellent chemi-

cal resistance and has been used for many years for the safe

transport of sewage and wastewater.

Other key advantages of this material that is normally died black

are its UV stability and flexibility.

PE 100

PE 100 is often referred to as a polyethylene of the third genera-

tion, or MRS-10 material. It has been developed from standard

PE by means of a modified polymerisation method and adapted

molecular weight distribution. PE-100 materials therefore do not

only feature a higher density, but offer also improved mechani-

cal properties such as increased stiffness and hardness. The

durability and resistance against slow and fast crack propagation

has also been improved significantly.

This material is therefore ideally suited for the production of

large-diameter sewage pipes.

FRANK GmbH is committed to best material and production

quality. We therefore decided several years ago to use only PE

100 for the production of our sewage pressure and PKS® pipes

and fittings.

Physiological safety

Polyethylene (and polypropylene) are food-grade materials

that meet the relevant standards (BGA and KTW regulations).

PE pipes and fittings are therefore approved for use in drinking

water distribution networks.


Structural formula of PE

Advantages of PE

� Low specific weight of 0.95 g/cm3

(resulting in low pipe weight)

� Easy to transport (e.g. in bundles)

� Excellent resistance to chemicals

� Weather-proof

� Radiation resistant

� Extremely easy to weld

� Excellent abrasion resistance

� No risk of deposits or blockage

� Low pressure drop due to

low friction factor (in contrast to metal pipes)

� Frost-resistant

� Ideal for thermoplastic forming

(e.g. deep-drawing)

� Rodent-proof

� Resistant to microbiological corrosion

� Suitable for media temperatures up to 60°C

4.1 Polyethylene

UV resistance

Pipes made in PE are weather-resistant and do not become

damaged by UV light (black PE pipes). Black PE pipes can

therefore be stored and installed outdoors, as the material does

not deteriorate when exposed to the elements.

Radiation resistance

Pipes made in polyethylene are resistant to high-energy radia-

tion. PE pipes have for example been used for many years for

the transport of radioactive wastewater from specialist labs and

as cooling water lines in nuclear power plants.

Normally radioactive wastewater emits beta and gamma radia-

tion. Tests have shown that PE pipelines do not become radio-

active, even after having been in use in nuclear plants for years.

Provided that they are not exposed to a uniformly distributed

dose of more than 104 gray over its service life, PE pipes can

also be used in areas with higher radiation activity.


Fig. 53 - SURE INSPECT RC - sewer pipe made in PE 100-RC with yellow inner lining for easy inspection

Fig. 54 - PKS® pipe with electrically conductive inside layer


4.1 Polyethylene

Hydraulic properties

The hydraulic properties of PE pipes are primarily determined by

the smooth, anti-adhesive inside surface of the pipe, whereby

the pipe cross-section can be calculated on the basis of a sur-

face roughness of k < 0.01 mm.

Abrasion resistance

Wastewater often contains substantial amounts of abrasive

substances such as sand and grit. PE 100 (as well as PP) offer

great resistance to abrasion. This has also been demonstrated

in abrasion tests performed according to the Darmstadt method

(see chapter 5.3 "Abrasion resistance", page 35).

Resistance to chemicals

As PE is a non-polar polymer, it is highly resistant to chemicals

in water and other media. PE does not react in any way with

aqueous solutions of salts, and non-oxidising acids or alkaline

substances.

Up to a temperature of 60° C, PE is also resistant to most sol-

vents. For detailed information, please refer to our catalogue

for plastic pipe systems or contact our technical department.

Modified polyethylene PE-el(electrically conductive polyethylene)

Pipes used to transport dust or other highly flammable sub-

stances must be earthed to prevent electrostatic charging.

By equipping pipes with a special co-extruded inside layer, it is

possible to produce PKS® sewage pipes (PE 100) that are elec-

trically conductive at the inside. Both the surface and volume

resistivity are within the limits generally required for electrically

conductive surfaces.

The actual earthing connections for PKS®-el pipes must be de-

termined in cooperation with our technical department.


General properties of polypropylene

When transporting media at a high

temperature, polypropylene might

be more suitable than polyethylene.

Pipes made in polypropylene (PP)

are high heat stabilised and there-

fore particularly suitable for sewage

systems where temperatures up to

95°C might occur.

Radiation resistance

Polypropylene can be affected by long-term exposure to high-

energy radiation.

Such radiation might lead to temporary brittling of the material as

its molecular structure becomes more closely crosslinked. Long-

term exposure to radiation however results in the breakup of the

molecular chains and a permanent weakening of the polymer

structure. This effect can be taken into account by applying a

reduction factor that must be determined empirically.

Absorbed doses of less than 104 gray cause however no signifi-

cant reduction in the strength of polypropylene.

Resistance to chemicals

PP is normally resistant to a large number of acidic and alkaline

substances, including phosphoric acid and hydrochloric acid.

Hydrocarbons can however damage PP pipes, as the material

tends to swell by up to 3 % when in contact with such sub-

stances. Polypropylene pipes are therefore not suitable for the

transport of petrol and other petrochemicals. The material also

reacts with free chlorine and ozone.

Thanks to its high temperature resistance, PP is widely used in

pickling units, chemical processing plants and for the transport

of highly aggressive effluents.

A s t h e c h e m i c a l r e s i s t a n c e o f a m a t e r i a l i s a l -

ways determined by the actual operating tempera-

ture, operating pressure and other external influences,

its suitability for a particular application must always be deter-

mined with these factors in mind.

If you have any queries regarding the suitability of PP for a specific

application, please contact our technical department for advice.


Advantages of PP

� Low density of 0.91 g/cm3 (PVC: 1.40 g/cm3)

(resulting in low pipe weight)

� High durability


� Dyeable with TiO2 pigments

� High resistance to ageing

� Easy to weld

� Excellent abrasion resistance

� Smooth inside surface preventing

deposits

� Low pressure drop due to

low friction factor (in contrast to metal pipes)

� Non-conductive, no damage

to molecular structures from leakage current

� Ideal for thermoplastic forming

(e.g. deep-drawing)

� PP is a poor thermal conductor, which

means that there is normally no need for

insulation around hot water pipes

� Suitable for media temperatures up to 95°C

� Rodent-proof

� Resistant to microbiological corrosion

4.2 Polypropylene

Structural formulaof PP

UV-resistance of PP

Pipes made in grey polypropylene are not UV-stabilised and

must therefore be protected against direct sunlight. PP pipes

for underground installation do not require any special protec-

tion against UV radiation, in contrast to overground installation,

where special protective measures must be taken. When storing

PP pipes outdoors for a prolonged period of time, they must be

covered with light-tight foil.

TSC pipes are black at the outside, which makes them UV-

resistant.


Property Standard Unit PE 100 PE 100 RC PE-el PP-R PP-B

Density at 23°C DIN EN ISO 1183 g/cm³ 0.96 0.96 0.99 0.91 0.91

E modulus (tensile test)Short-termLong-term (50 years)

DIN EN ISO 178 N/mm² 1100200

1100200

1400-

900287

1850290

Tensile stress at yield DIN EN ISO 62:2008-05 N/mm² 23 23 26 25 33

Tensile strength at break DIN EN ISO 62:2008-05 N/mm² 38 - 30 - -

Elongation at break DIN EN ISO 62:2008-05 % > 600 - - - -

Ball impression hardness DIN EN ISO 2039 N/mm² 46 - 40 - -

Notched impact strengthat 23°C (Charpy test)

DIN EN ISO 179/ DIN EN

ISO 180kJ/m² - 22 5 20 50

Creep resistance (FNCT) DIN EN 12814-3 h > 300 > 8760 - - -

Melt flow indexMFR 190/5 (°C/kg)MFR 190/21,6 (°C/kg)MFR 230/2.16 (°C/kg)MFI group

DIN EN ISO 1133Code TCode GCode M

g/10 min0.3--

T005

0.25--

-4.5-

M003

--

0.25

--

0.30

Coefficient of elongation DIN 53752 k-1 x 10-4 1.8 1.8 - - -

Fire class UL94 DIN 4102 - 94-HB

B294-HB

B294-HB

B294-HB

B294-HB

B2

Thermal conductivity (at 20 °C) DIN 52612 W/mK 0.38 0.38 0.43 0.24 -

Specific volume resistivity

DIN IEC 60093DIN IEC 60167 Ohm cm > 1015 > 1015 > 105 - -

Surface resistivity DIN IEC 60093DIN IEC 60167 Ohm > 1013 > 1013 > 104 - -

Colour - - Black/yel-low Black Black Grey

(RAL 7032) Black/grey

MRS rating DIN EN ISO 9080 N/mm² 10 10 - - -

Electric strength DIN EN VDE 0303 kV/mm 70 70 - - -

Mechanic

al

pro

pert

ies

Therm

al

pro

pert

ies

Ele

ctr

ical

pro

pert

ies

Table 4 - Material properties of plastics (guide values)


4.3 Material properties

Materials used in the production of sewage pipe systems must

have the following properties (guide values):


5.1 Creep rupture curves - DIN 8075 PE 100 pipes


service life [h]

co

mp

ariso

n s

tress

σv

[N/m

m²]

service life [year]

Fig. 55 - Creep rupture curve - PE 100


5.2 Creep rupture curves - DIN 8078 PP-R pipes

5. Resistance to pressure and wearco

mp

ariso

n s

tress

σv

[N/m

m²]

service life [h]

service life [year]

Fig. 56 - Creep rupture curve - PP-R


General

Sewage pipe systems carry wastewater and rain water, which contain abrasive substances such as sand and grit. As wastewa-

ter systems are crucial for the protection of the environment and are costly investments they must work properly and reliably for

a long period of time. This can be achieved by opting for permanently tight pipe systems made in high-quality materials and by

regular cleaning and maintenance.

To withstand the impact of solids, pipes must be made from a material that is resistant to abrasion, as premature wear of the pipe

tends to lead to leakage. FRANK pipes are made from PE 100 and PP that have a high resistance to abrasion as has been proven

in abrasion tests performed according to the Darmstadt method.


5.3 Abrasion resistance

Evaluation:

The abrasion is measured with a dial gauge (scale 0.01 mm)

along the base of the pipe. The depth of the abrasion is thereby

measured along a length of 700 mm, as the two 150 mm sec-

tions near the ends of the pipe are not taken into account. The

measurements are taken at distances of maximum 10 mm

and the average abrasion depth is calculated. This value thus

represents the average difference between the new pipe wall

thickness and the actual wall thickness after testing. The excel-

lent abrasion resistance of PE and PP compared with other pipe

materials is shown clearly in the diagram below:

Testing according to the Darmstadt method

The Darmstadt method has been devised for the abrasion test-

ing of pipes and conforms to the relevant standards.

Test layout:

With the Darmstadt method, a 1000 mm half-pipe section is

mounted in the testing device. The ends of the section are closed

with end plates and filled with a mixture of sand and gravel.

To conform to the standard, the test must be performed with

natural, unbroken, round-grained quartz gravel. The half-pipe

is then closed with a lid and tilted alternatively by 22.5° along its

transverse axis so that the sand/gravel mixture is moved along

the inside surface of the pipe.

For the test, an average of 400,000 tilting cycles must be per-

formed.

Fig. 57 - Test layout for abrasion testing Fig. 58 - Diagram of mean abrasion

mean abrasion am in mm

concrete pipe GRP pipe

stoneware

PVC pipe

PP and PE pipe

number of load cycles

concrete pipe with MC-DUR liner

cover platefront plate

cover plate



5.3 Abrasion resistance

Results

PKS® sewage pipes according to DIN 16961 / DIN EN 13476,

FRANK & KRAH

The abrasion test was performed with a profiled sewage pipe

(PE 100), size DN 300. The discolouration at the bottom of the

pipe indicates minor abrasion.

Before - 0 test cycles After - 100,000 test cycles

As part of our quality assurance systems, we perform internal tests and also have our products tested by independent testing

bodies. One of the test parameters is the abrasion resistance of our raw/moulding materials. The specimens are normally DN 300

sections taken from a normal production run at one of our plants.

For the evaluation of the results, the values are adjusted to 100,000 test cycles. This corresponds to the actual abrasion in an

installed pipe over a period of 25 years.

Before - 0 test cycles After - 100,000 test cycles

PP pipes according to DIN 16961 / DIN EN 13476, FRANK & KRAH

In other tests, a pipe made in PP, size 300 was examined. The

picture to the right shows minor abrasion (discolouration at the

bottom of the pipe).

Abrasion caused during the tests appear as lighter coloured sections inside the pipe halves.

The results of the two tests show that the actual abrasion depth is more or less proportional to the number of test cycles. The

measurements of the two tested pipes show a mean abrasion depth of 0.09 mm after 100,000 test cycles. This value is significantly

below those measured in other materials.

Fig. 59 - PKS® pipe (PE 100), DN 300 in abrasion test, FRANK & KRAH Wickelrohr GmbH

Fig. 60 - PP pipe, DN 300 in abrasion test, FRANK & KRAH Wickelrohr GmbH


5.4 Resistance to high pressure cleaning


High pressure system test - layout

The tests were performed using conventional cleaning vehicles,

flushing hoses and cleaning nozzles and with a pressure of 120

bar at the nozzle and a flow rate of 320 l/min. The nozzle was

moved through the pipe system at a rate of 1 m/s (forward)

and 0.1 m/s (return). These parameters are at the upper end of

load that might occur during standard pipe cleaning. In addition,

grit was added at each test cycle. This material is accelerated

by the water jet and the propelled air, impacts on the pipe wall,

connections and inlets and eventually escapes at the other end.

This was done to simulate the effect of deposits in the pipe.

All pipe strings also underwent a stationary test with a point

load. In this test, three points along the pipe were selected and

the nozzle was placed for three minutes above these points to

produce a point load.

All nozzle point load tests were performed with the same type

of nozzle (circumferential, eight-jet nozzle with a jet angle of 30°

(test nozzle D1 8 x 30°)) and for the same time period. The test

was performed over 50 cleaning cycles (forward and return

movement of the nozzle). This corresponds to the number of

cycles that are normally expected over the service life of a sewer

line of 100 years (cleaning every two years).

Introduction

As wastewater is not a homogeneous solution and the flow rate in most sewage pipes fluctuates, deposits are to be expected

and might differ greatly in composition and structure. Normally, deposits in pipes consist of a mixture of mineral and organic

matter, including small stones. That is why sewage pipe system operators regularly clean their pipelines. A number of differ-

ent methods have been devised for this task over time. Today, most operators use high pressure cleaning, as this is the most

economical method. However, high pressure cleaning places a high load on the sewage pipe system. To ensure that a pipe

system is suitable for high pressure cleaning, a standardised test method known as the Hamburg model has been devised.

During high pressure cleaning, pipe systems must withstand a number of stresses and impacts. Pipes can become mechanically

worn by the nozzle and high-pressure hose that pass along the bottom of the pipe during the cleaning process. As deposits

are moved along the bottom of the pipe is normally, abrasion from solids is increased.

To determine the effect of high pressure cleaning on the pipe material, a number of tests have been devised. In order to obtain

results that reflect the actual conditions during high pressure cleaning, the pipes are tested following the Hamburg model. In

2004, Institut für Unterirdische Infrastruktur GmbH (IKT) in Gelsenkirchen published a scientific study that examined various pipe

materials as regards high pressure cleaning resistance. The study report is available from IKT.

Results of tests

For the high pressure cleaning test, IKT used PKS® pipes with a

smooth, extruded solid wall made in PE 80 and light-coloured

inside layer, size DN 300/da 355.

Reference high pressure cleaning tests carried out without grit

show only minor marks along the bottom of the PE pipes near

the connections, caused by the moving nozzle jet. Subsequently,

a volume of 5 litres of grit was added at each cleaning cycle.

The bottom of the pipe and the connections now showed more

prominent abrasion marks and the pipe surface became rough-

er. The actual abrasion depth remained however below 1 mm.

The pipe strings also underwent stationary tests whereby the

nozzle was pointed for 3 minutes to the same point in the pipe.

This load did have no discernible effect on the material.

The test results show that PE pipes can withstand normal loads

and abrasion over a lifespan of 100 years without any significant

damage. The wear resistance of PE is therefore considerably

higher than that of conventional pipe materials, some of which

showed significant abrasion.


Operating conditions Recommended for PEkb

according to DWA-A 110kb

Throttle sections, pressure pipelines, culverts and relined sections without manholes 0.10 mm 0.25 mm

Transport pipelines with manholes according to DVWK M 241 section 1.1.5, e.g. PKS® tangential manhole made in PE 100

0.25 mm 0.50 mm

Main sewers and pipelines with manholes according to DVWK M 241 section 1.1.5 up to DN 1000; with form-fitted manholes according to DVWK M 241 section 8.1.2.3 for all DN; transport pipelines with special or integrated man-holes for all DN

0.50 mm 0.75 mm

Main sewers with supply pipes, special manholes and spe-cial angles 0.75 mm 1.50 mm

6.1 Determination of pipe cross-section for gravity pipelines

Thanks to the outstanding properties of plastic pipes, they can

be used for the construction of sewer lines with a very small

angle of inclination. For the hydraulic dimensioning of PE pipes,

follow the DWA guidelines. The waxy, smooth inside surface of

the PE pipes prevents sediments.

Pipes might be partially or fully filled. Normally, the maximum

possible flow rate in fully filled pipelines is taken into account.

Operational roughness kb

Following the DWA guidelines, the calculations for sewer lines

must be based on the operational roughness kb, as it includes

the effect of manholes and fittings on the flow rate. For PE pipes,

the recommended value kb = 0.1 mm provides an adequate

safety margin.

Q = v . A

6. Calculations

General mean roughness kb for various operating conditions

The kb values include the effects of pipe joints, deviations from the planned pipe position, wall roughness, inlet fittings and man-

hole structures.

The maximum drainage rate v is determined according to

PRANDTL and COLEBROOK:

The maximum discharge Q of a fully filled pipeline is:

v ... Flow rate [m/s]

JE ... Energy gradient

kb ... Operational roughness [mm]

g ... Gravity [Nm/s²]

n ... Kinematic viscosity [m2/s]

(1.31 x 10-6, for sewage at 12°C)

DN ... Inside diameter [mm]

Q ... Discharge [l/s]

A ... Flow cross-section area [mm²]

v ... Flow rate [m/s]

Table 5 - Mean roughness kb for PE


6. Calculations

6.2 Stress resulting from insulation and groundwater above pipe level

In certain exceptional cases, a pipeline system might be exposed

to an external underpressure:

� If it is installed in water (culvert) or in the ground below the

groundwater horizon

� During the insulation of a relined pipe

� If a pump is installed at the suction side of the pipeline (un-

derpressure in pipe)

Groundwater level

ph, w

In insulated pipes, the insulation supports the pipe, so that its

buckling pressure is higher than that of a non-insulated pipe.

The static stress on a sewer pipeline restored by means of PE

pipes can be calculated using the pk equation:

pk ... Critical buckling pressure [bar]

EC ... Creep modulus (see page 41) [N/mm2]

m ... Transverse contraction coefficient

(for thermoplastics: generally 0.4)

s ... Equivalent wall thickness [mm]

rm ... Mean pipe radius [mm]

The effects of eccentricity and unroundness must be taken

into account by applying a reduction factor fr, which is normally

between 0.9 and 0.95.

For stability calculations, for example to calculate the buckling

pressure, a minimum safety factor of 2 must be applied.

3

m2

Ck r

s)1(4

E10p �

�

��

��

��

��

pk, zul Permissible critical buckling pressure

[bar]

fr ... Reduction factor (0.9 to 0.95)

S ... Safety coefficient (≥ 2)

sk ... Buckling stress [N/mm²]

pk ... Permissible critical buckling pressure [bar]

rm ... Mean pipe radius [mm]

s ... Wall thickness [mm]

Where PE pipes are insulated, there is a risk that the pipe might

become buoyant so that it is not in the envisaged position. To

prevent this, pipe sections can be equipped with spacers that

prevent the pipe from floating. In this case, the loads on these

spacers must be calculated. The spacer distance must be cho-

sen so that the maximum permissible deflection is not exceeded.

Lifting force acting on PE pipes filled with water:

FV ... Lifting force [N]

daR... Outside pipe diameter [mm]

DN ... Inside pipe diameter [mm]

γD ... Specific weight of insulation [kg/dm³]

lR ... Support span [m]

For PE pipes the buckling pressure pk is:

Lifting force acting on empty PE pipes:

LA ... Maximum support span [mm]

fLA ... Deflection factor (0.80)

EC ... Creep modulus (see page 41) [N/mm²]

JR ... Pipe moment of inertia [mm4]

q ... Buoyancy load [N/mm]

The permissible buckling pressure is:

The buckling stress can subsequently be calculated as follows:

Maximum distance between support points

Fig. 61 - Load resulting from hydrostatic pressure resulting from groundwater above pipe level (e.g. for pipes installed below groundwater horizon)


Standard ve-hicle Total load Wheel

load Wheel footprint

[kN] [kN] Width[m]

Length[m]

HGV 60 600 100 0.6 0.2

HGV 30 300 50 0.4 0.2

CV 12 120 front 20rear 40

0.20.3

0.20.2

6.3 Calculations for underground sewage pipes according to ATV-DVWK-A 127

ATV-DVWK-A 127

Plastic pipes made in polyethylene or polypropylene are normally

installed underground. As the loads on the pipe can be varied

and changing, the stability calculations are normally performed

by means of specialised computer software. As a rule, the

calculations must be carried out according to the instructions

in ATV-DVWK-A 127 "Static Calculations of Drains and Sew-

ers". In order to perform accurate and complete calculations

for underground PKS® pipes, it is necessary to know the actual

installation conditions.

To determine these, please refer to the questionnaire in chap-

ter 7, pages 44 ff. On request, FRANK GmbH shall perform

verifiable calculations based on your information provided in

the questionnaire.

Installation

For the calculation, the type of installation must be taken into

account in addition to the outer and inner stress factors. The

deformation of underground sewage pipes is greatly affected by

the structure and material of the bedding. As a rule, the bedding

angle should be as large as possible. Possible bedding angles

are 120° and 180°.

Most underground sewage pipes are installed in a trench.

Depending on the site conditions and requirements, different

trench types and shapes are used. For the calculation of the

pipe stress, the shape of the trench must be determined (see

examples below).

2α

b

β

b

h

hTrench with sloped walls

Trench with parallel walls

h

6. Calculations

For the determination of the load, ATV-DVWK-A 127 uses the following standard vehicles:

Loads

For calculations according to ATV-DVWK-A 127, a number of

different loads might need to be considered, including:

� Road traffic loads

� Rail traffic loads

� Top covering loads

� Surface loads from buildings

� External water pressure

Road traffic loads

Apart from the top covering load, road traffic loads are the most

common loads on underground sewage pipes, as most pipelines

are driven over by road vehicles. According to ATV-DVWK-A

127, it is therefore necessary to assume a road traffic load of

minimum of CV 12 even for pipes that are not strictly speaking

in a road traffic area.

Fig. 62 - Bedding angle

Fig. 63 - Trench installation

Fig. 64 - Installation in bankTable 6 - Load assumptions for standard vehicles


6.3 Calculations for underground sewage pipes according to ATV-DVWK-A 127

Soil classes

The soil groups required for the calculation are laid down in DIN

18 196:

G1: Non-cohesive soils (gravel, sand)

[GE, GW, GI, SE, SW, SI]

G2: Slightly cohesive soils (mixtures of gravel and sand

with clay and silt)

[GU, GT, SU, ST]

G3: Cohesive mixed soils, coarse clay (cohesive sand

and gravel, cohesive stony residual soil)

[GU, GT, SU, ST, UL, UM]

G4: Cohesive soils (clay, loam)

[TL, TM, TA, OU, OT, OH, OK, UA]

Trench zones

The pipeline trench consists of the following zones:

Zone 1: Trench filling above the top of the pipe

Zone 2: Pipe zone to the side and below the bottom of the pipe

Zone 3: G r o u n d a d j a c e n t t o t h e t r e n c h o r s o i l

installed beside the pipe zone

Zone 4: Ground below the pipe (trench base)

For the calculation according to ATV-DVWK-A 127, it is necessary

to determine compaction rate (Proctor density) and the soil type

of the above zones (see questionnaire page 45).

Covering and embedding conditions

For the embedding of the pipe zone and the backfilling of the

trench above the pipe zone, ATV-DVWK-A 127 distinguishes be-

tween 4 covering conditions (A) and 4 embedding conditions (B):

A1/B1. Compacted embedding in layers against the natural

soil or in the embanked covering (without verification

of degree of compaction); applies also to beam pipe

walls ("Berlin shuttering").

A2/B2. Vertical shuttering in the pipe trench using trench sheet-

ing or lightweight piling profiles, which is only removed

after backfilling. Shuttering plates or equipment are

gradually removed as the trench is being filled. Un-

compacted trench backfilling. Hydraulic installation of

backfilling/embedding material (only suitable for soil

group G1).

A3/B3. Vertical shuttering in the pipeline zone, using sheet pil-

ing or lightweight piling profiles, wooden planks, riveting

plates or similar equipment, which are only removed

after backfilling; no effective re-compaction after re-

moval of the above equipment.

A4/B4. Compacted embedding in layers against the natural

soil or in the embanked covering, with verification of

degree of compaction (Proctor density) as required

according to the German Technical Terms and Condi-

tions of Contract and Guidelines for Earthworks in Road

Construction ZTVE-StB; applies also to beam pipe walls

("Berlin shuttering"). Covering/embedding condition A4/

B4 is not permissible for soils of group G4.

E2Zone 2

E1Zone 1

E3Zone 3

E4Zone 4

E3Zone 3

6. Calculations

Fig. 65 - PKS® sewage pipe installed in pipe trench Fig. 66 - Pipe trench zones


p20dp

szul

min ��

�

C1

Vzul ��

6. Calculations

6.4 Calculation of pipe wall thick-ness smin based on operating pressure

The wall thickness is calculated with the boiler formula. To

determine the design stress (σzul), use the reference stress

(σV) shown in the respective service life curves (pages 31, 32)

and divide it by the safety coefficient C (according to DIN 8077).

Depending on actual application, it might be necessary to include

a system reduction coefficient (0.8). This additional safety coef-

ficient enables you to take into account additional stresses at

joints (e.g. welded connections):

6.5 Stress due to external overpres-sure (buckling pressure)

In certain exceptional cases, a pipeline system might be exposed

to an external overpressure:

� Pipeline installed below water level or below the groundwater

horizon

� Underpressure pipelines, e.g. suction lines

The permissible underpressure is determined as follows:

smin .... Minimum wall thickness [mm]

p .... Operating pressure [bar]

d .... Outside pipe diameter [mm]

σzul .... Design stress [N/mm2]

pB .... Permissible buckling pressure [bar]

Ec .... Creep modulus [N/mm2]

(the creep modulus must be determined from the diagrams

on page 41; the value determined from the diagram must be

divided by 2)

µ .... Transverse contraction coefficient

(for thermoplastics: generally ~0.4)

s .... Wall thickness [mm]

rm .... Mean pipe radius [mm]

If required, the above values allow for the calculation of the ac-

tual stress σtat or the maximum operating pressure p at a

given wall thickness s:

min

minzul

sds20

p�

��

The buckling stress is calculated as follows:

2C

2zul

min )E(1

20dp

s��

��

�

Ec .... Creep modulus (see page 41) [N/mm2]

ε .... Elongation = ∆L/L0

∆L .... Elongation [mm]

L0 .... Pipe length [mm]

σB .... Buckling stress [N/mm2]



s .... Wall thickness [mm]

For rigidly secured sewage pipe systems, the required mini-mum wall thickness smin must be calculated with the following

formula:

The minimum wall thickness can be calculated with the fol-

lowing formula:

The minimum wall thickness is calculated as follows:


Ec .... Creep modulus [N/mm2]

(the creep modulus must be determined from the diagrams

on page 41; the value determined from the diagram must be

divided by 2)

smin .... Minimum wall thickness [mm]


For hazardous media, the permissible stress must be reduced

by the associated reduction coefficients.


6.6 Creep rupture curves for PE 100 according to DVS 2205-1

6. Calculations

1 year

working temperature [°C]

Cre

ep

mo

dulu

s [N

/mm

²]

10 years


Cre

ep

mo

dulu

s [N

/mm

²]

start

of

ag

ein

g

25 years


Cre

ep

mo

dulu

s [N

/mm

²]

start

of

ag

ein

g

Reduction of creep modulus

For stability calculations, the creep modulus determined from

the diagrams shown here must be reduced by a safety coef-

ficient of > 2. The effects of chemical influences, eccentricity or

unroundness must be taken into account separately.

Creep rupture curves for PP

The creep modulus is mainly determined by the materials used

in the pipe. For pipes made in PP, special raw materials that have

a higher creep modulus than specified in DVS 2205-1 are used.

For a rough calculation, the value stated in DVS 2205-1 can be

applied. Exact creep modulus figures are available on request.

Fig. 67 - Creep rupture curve for PE 100, service life 1 year Fig. 68 - Creep rupture curve for PE 100, service life 10 years

Fig. 69 - Creep rupture curve for PE 100, service life 25 years


L)1d/d(E)21(p1,0

L2i

2C

p ��

��

Elongation due to changes in temperature

The elongation of the pipe resulting from changes in temperature

is calculated as follows:

6.7 Calculation of elongation

6. Calculations

Elongation due to internal pressure

The longitudinal expansion caused by internal overpressure in

a sealed pipeline that has no friction is:

L ... Pipeline length [mm]

p .... Operating pressure [bar]

µ .... Transverse contraction coefficient

EC ... Creep modulus [N/mm2]

d .... Outside pipe diameter [mm]

di ... Inside pipe diameter [mm]

Elongation due to chemical influences

Chemicals (e.g. solvents) transferred through the pipe can lead

to elongation (due to swelling) of the pipe and an increase of its

diameter. This is accompanied by reduced mechanical strength.

For solvents, the expected elongation can be determined with

reasonable accuracy using a swelling coefficient. Based on the

extensive research regarding the behaviour of PE and PP sew-

age pipes filled with solvents, we recommend using a swelling

coefficient of:

L ... Pipeline length [mm]

fCh ... Swelling coefficient

∆T is the difference between the installation temperature and

the highest (lowest) operating temperature.

Mean value for α:

∆LT = α . L . ∆T

∆LT.... Elongation [mm]

due to change in temperature

α .... Linear coefficient of expansion [mm/m.K]

L .... Pipe length [m]

∆T Temperature difference [K]

The actual coefficients of expansion depend on the temperature

and are listed in our catalogue of plastic sewage pipe systems.

Note:

The elongation values and associated bending leg lengths are shown

in the nomograms in our catalogue of plastic sewage pipe systems.

PP ~ 0.16 mm/m·K = 1.6·10-4 1/K

PE ~ 0.18 mm/m·K = 1.8·10-4 1/K

Note:

For the exact calculation, the applicable swelling factor must be

determined by means of material tests.

fCh = 0.025 ... 0.040

∆LCh = fCh . L

The elongation due to swelling can thus be determined as fol-

lows (approximate calculation):


Fixed points are designed to prevent the pipe from moving

in any direction. They also absorb reactive forces in systems

where compensators, plug sockets or sliding sockets are used.

The fixed point must be suitably dimensioned to withstand all

occurring forces:

� Forces generated by obstructed elongation

� Weight of vertical pipeline sections

� Specific weight of medium in pipe

� Operating pressure

� Intrinsic resistance of expansion compensators

Fixed points must be positioned in such a way that bends in

the pipeline can be utilised for the purpose of elongation com-

pensation.

The edges of sockets of fittings and special fixed point fittings

have proven must suitable for this task. In profile sewage pipe

systems, the profiles at the outside of the pipe can serve as fixed

point structures (e.g. with concrete counter bearing).

Rigidly secured systems

Systems where elongation of the pipeline is prevented are re-

ferred to as rigidly secured systems. The rigid or rigidly secured

pipeline section does not include any compensation elements

and must be dimensioned accordingly as a special construction.

The following system parameters must be calculated:

� Fixed point load

� Permissible guide bearing distance, taking into account criti-

cal buckling length

� Occurring tensile and pressure stress

Pipes made of the special materials PE-el and PP-s-el can only

be used in rigidly secured systems, if the tensile stress is minimal.

For all other materials, we recommend using expansion bends

to compensate the elongation.

Fixed point load in rigidly secured systems

The fixed point load is highest along straight, rigidly secured

pipeline sections. It can be calculated with the following formula:

FFP = AR . EC . ε

FFP ... Fixed point force [N]

AR ... Inside wall surface area [mm2]

EC ... Creep modulus [N/mm2]

ε ... Prevented elongation caused by

thermal expansion, inside pressure or swelling

6. Calculations

6.8 Fixed points in exposed pipelines

For additional information and formulas for the calculation and

dimensioning of plastic pipes, please refer to our catalogue of

plastic sewage pipe systems.

It contains the details regarding:

� Permissible component operating pressures pB for PE 100

and PP with reference to temperature and service life

� Comparison of application limits for pipelines made in PE 100

and PP over a service life of 25 years

� Application coefficients fAP for water pollutant media and

reduction coefficient A1 for media that become viscous at

low temperatures (following DVS 2205-1)

� Media list with chemical resistance coefficients fAZ=1 (accord-

ing to DVS 2205-1)

� Chemical resistance coefficients fAZ for chemicals flow (ac-

cording to DVS 2205-1)

� General chemical resistance with special reference to acidic

and alkaline substances

� Calculation of pipe cross-sections for pressure pipelines

� Calculation of hydraulic loss

� Resistance coefficient of pipe fittings

� Flow nomogram (for water) for the rough calculation of the

flow rate, pressure drop and discharge rate

6.9 References


7.1 Static load questionnaire for the calculation of underground sewage pipes according to ATV-DVWK-A 127

Project:

Location:

Client:

Contact person: Phone:

Pipe:

PKS® profiled sewage pipe: Inside pipe diameter DN: mm

Extruded solid wall pipe: Outside pipe diameter da: mm

Wall thickness s: mm

Length of pipeline m

Pipe material: PE 100 PP-R

Loads:

Flow medium:

Specific weight: g/cm3

Medium temperature: during operation TB: °C

maximum Tmax: °C

Operating pressure pü: bar

Service life: 50 years or years:

Road traffic load: none HGV 60 HGV 30 CV 12

Additional surface load N/mm2

Groundwater level above bottom of trench:

mm

Filled with water(e.g. storage capacity system):

yes no

Comments:

Project details:

7. Static strength questionnaire/manhole data sheet


E1

E2 E2

E4

E3E3

Zones:

Trench Trench width (w): mm

Slope angle (β): °

Covering height (h): mm

Installation:

b

β

h

Bank Covering height (h): mm

h

Covering and embedding conditions:

Covering

A1

A2

A3

A4

Embedding

B1

B2

B3

B4

Support:

Bedding angle 2α: 120°

180°

2α

Soil:

Soil Soil type E1 E2 E3 E4

Group:G1 - non-cohesive soils (sand, gravel) G1 G1 G1 G1

G2 - slightly cohesive soils (sand, gravel) G2 G2 G2 G2

G3 - cohesive mixed soils, coarse clay G3 G3 G3 G3

G4 - clay, loam G4 G4 G4 G4

Note: In zone E2, sand (G1) should be used!

Specific weight [g/cm3] .......... .......... .......... ..........

Degree of compaction (85 % to 100 %), % Dpr, preferably > 97 %

.......... .......... .......... ..........

E modulus EB [N/mm2] .......... .......... .......... ..........

7. Static load questionnaires/manhole data sheet

7.1 Static load questionnaire for the calculation of underground sewage pipes according to ATV-DVWK-A 127


h2

hw

h1

bA

Project:

Location:

Client:

Contact person: Phone:

Project details:

Manhole diameter (DN): mm

Installation depth (h1) mm

Length of manhole pipe (h2) mm

Height of groundwater level (hw) mm

Casing area (bA) mm

Density of embedding material: g/cm3

Slope of terrain: °

Manhole sleeve material: PE 100 PP-R

Installation:

Soil:

Soil group

Proctor density

Known E modulus

Natural soil

G1 G2 G3 G4

%

N/mm2

no traffic load

HGV 30

HGV 60

other

Impact factor

Road traffic load:

Embedding

G1 G2

%

N/mm2

On cover

kN

Adjacent to manhole

kN


7.2 Static load questionnaire for the calculation of underground plastic man-holes following ATV-DVWK-A 127


without bottom plate with simple bottom plate with complete casing

with concrete casing

put-on coverstandard concrete cone

separately supported over

with PE flat roof

hf

hb

ha

hf

hb

hf

hb

Manhole floor:

Thickness of concrete slab (hb) ......................... mm

Thickness of concrete bottom plate ......................... mm

Height of concrete ring (ha) ......................... mm

Concrete class of bottom plate ......................... mm

Concrete filling (hf) ......................... mm

Diameter Wall thickness Angle

Through-pipe mm mm °

1st spigot mm mm °

2nd spigot mm mm °

3rd spigot mm mm °

4th spigot mm mm °

Spigot:

Manhole cover:

no cover


7.2 Static load questionnaire for the calculation of underground plastic man-holes following ATV-DVWK-A 127


7.3 Explanations re. questionnaires

Covering conditions for trench backfilling

There are 4 covering conditions A1 to A4 for the backfilling of the trench above the pipe level:

A1: Filling/covering of trench in layers against the natural soil (without verification of degree of compaction)

A2: Vertical shuttering in the pipe trench using trench sheeting or lightweight piling profiles, which is only removed after backfilling. Shuttering plates or equipment are gradually removed as the trench is being filled. Uncompacted trench backfilling. Hydraulic installation of embedding material (only suitable for soil group G1)

A3: Vertical shuttering in the pipe trench using sheet piling, wooden planks, riveting plates or similar equipment that are only removed after backfilling.

A4: Compacted trench backfilling/covering in layers against the natural soil, with verification of Proctor density according to ZTVE-StB. Covering condition A4 is not permissible for soils of group G1.

Safety classes

Safety class A (standard safety class)

� Potential risk of groundwater pollution � Restricted use � Failure would have significant economic

consequences

Soil types

Soils are classified in the following groups (in square brackets: codes according to DIN 18 196):

Group 1: Non-cohesive soils (gravel, sand) [GE, GW, GI, SE, SW, SI]

Group 2: Slightly cohesive soils [GU, GT, SU, ST]

Group 3: Cohesive mixed soils, coarse clay (cohesive sand and gravel, cohesive stony residual soil) [GU, GT, SU, ST, UL, UM]

Group 4: Cohesive soils (clay, loam) [TL, TM, TA, OU, OT, OH, OK, UA]

E1 Trench filling above the top of the pipe

E2 Pipe zone to the side of the pipe

E3 Ground adjacent to the trench or soil installed beside the pipe zone

E4 Ground below the pipe

E2

E3E3

E2

E4

E1


Safety class B (special safety class)

� No risk of groundwater pollution � Minor use restrictions � Failure would have minor economic consequences

Group Unit weight B Inner friction angle Deformation modulus EB in N/mm² at Proctor density Dpr in %

kN/m³ 85 90 92 95 97 100

G1 20 35 2.4 6 9 16 23 40

G2 20 30 1.2 3 4 8 11 20

G3 20 25 0.8 2 3 5 8 13

G4 20 20 0.6 1.5 2 4 6 10

Rev. Feb. 201648 December 2013 | Sewage pipe systems

Pipeline embedding

For the embedding of the pipeline sections, we distinguish between 4 embedding conditions B1 to B4:

B 1: Compacted embedding in layers against the natural soil or in the embanked embedding (without verification of degree of compaction).

B 2: Vertical shuttering in the pipe trench using trench sheeting or lightweight piling profiles, which is only removed after backfilling. Trench secured with shuttering plates or equipment, provided that soil can be properly compacted after removal of the shuttering. Hydraulic installation of embedding material (only suitable for soil group G1).

B 3: Vertical shuttering in the pipeline zone, using sheet piling, wooden planks, riveting plates or similar equipment, without effective re-compaction after removal of the above equipment.

B 4: Compacted embedding in layers against the natural soil or in the embanked embedding with verification of Proctor density according to ZTVE-StB. Embedding condition B4 is not permissible for soils of group G4.

Support

Support type 1

Installation

The calculation method is valid for pipelines that are installed, supported and embedded according to DIN 4033.

Outside of road traffic areas, CV 12 must be applied as the minimum load.

Loads and wheel footprints of standard vehicles

2α

7.3 Explanations re. questionnaires


Standard vehicle Total load Wheel load Wheel footprint

kN kN Width m Length m

HGV 60 600 100 0.60 0.20

HGV 30 300 50 0.40 0.20

CV 12 20 rear 40 0.30 0.20

front 20 0.20 0.20



7.4 Manhole data sheet

m ü. NN

Grundwasserstand m ü. NN

mm

m ü. NN

m ü. NN

Leiter B:_____ Wst:_____ Fallschutz

h= mm

h= mm

Intern:

h= mm

d= mm

d= mm

Gerinne Kämpferhoch

Befüllstutzen zur Verfüllung

Pumpensumpf DN:

Steigkästen im Gerinne

Gerinne Scheitelhoch

Einstiegshilfe

(2) Zulauf

(4) Zulauf

(3) Zulauf

(1) Auslauf

Pro

fil/S

DR

Stu

tze

n-

län

ge

vo

n in

ne

n

Ele

ktr

o-M

uff

e

So

hlh

öh

e

m ü

. N

N

DN

° A

lt-

Gra

d

Inn

en

-

he

ll

gekapseltes Fundament ø Bemerkungen:

DA

Ende

Bodenplatte (PE)

Tangentialschacht DN:

bestellt durch:

Schachtbezeichnung: Datum: Sachbearbeiter:

geplanter Liefertermin:

Firma: Bauvorhaben: Stück: Bauteil:

Hebeösen

Hebeösen mit Zentrierung

Stand 01/2010

(5) Zulauf

Steigtritte

Berme

Sp

itze

nd

e

Vo

rsch

we

iß-

bu

nd

+

Lo

sfla

nsch

Gla

tt

Profil___________

Re

du

ktio

n

Bemerkung

Au

fwic

klu

ng

au

f D

A

Schachtmantelrohr

FRANK GmbH

Starkenburgstr. 1

64546 Mörfelden-Walldorf

Deutschland

Telefon: 06036 / 9798-

Telefax: 06036 / 9798-351

Abdeckplatte /-konus

Fließsohle mit Schacht

GOK

OK PE-Schacht

Kontrollschacht DN:

Company: Project: Quantity: Component:

Estimated delivery date:

Description of manhole: Date: Person responsible:

Ordered by:

Top ground surface metres above sea level

Groundwater level metres above sea level

Cover plate / cone mm

PE manhole metres above sea level

Medium height of manhole

Shaft steps

Access shaft frames within channel

Ladder B: _________ Wst: _________

Entry aid

Lifting eyes

Berm

Pump sump pit DN: _________ h = _________ mm

Channel up to pipe crown

Channel up to pipe middle

Note: Optionally you can send a sketch.

End

DN

DA

° D

eg

ree

Pro

file /

SD

R

Leng

th o

f

ad

ap

ter

insi

de

IInsi

de

light-

co

loure

d

Flo

or

leve

l (m

etr

es

ab

ove

sea le

vel)

Ele

ctr

o-f

usi

on

socke

t

Sp

igo

t end

Sm

oo

th e

nd

Weld

ing

neck

+ lo

ose

flang

e

Red

uctio

n

Rew

ind

to

DA

Remarks

(1) outflow

(2) inflow

(3) inflow

(4) inflow

(5) inflow

Tangential manhole DN: _______ mm

Inspection manhole DN: _______ mm

Remarks:


8. Installation

8.1 General installation guidelines

Introduction

Sewage pipe systems are civil engineering constructions that need to meet a number of standards and regulations, among them

the current installation guidelines for pipe systems that apply in Germany, known as DWA-A 139.

Due to the light weight of PE and PP pipes and manholes and their stability, these elements can be handled with light equipment.

Plastic pipes are therefore particularly suitable for installation along narrow roads and in hilly areas, as they offer the most economi-

cal solution.

Transport

PKS® sewage pipes, fittings, manholes and special construc-

tion elements must be transported on suitable vehicles. During

transport, they must be properly secured against shifting on the

load platform. Ensure that other objects on the load platform do

not impact on the pipes. The load platform must be level and

free of any debris that could cause damage to the pipes. Special

care must be taken when loading and unloading the pipes to

prevent damage to the pipes.

Handling

Plastic pipes and fittings must be loaded and unloaded with

suitable lifting gear. Never allow pipes to drop to the ground.

Do not drag the pipes along the ground. When handling profiled

sewage pipes, pay attention to the sockets and spigot ends

as they must not become dirty or damaged. Pre-assembled

components (e.g. storm water tanks) must be lifted by the at-

tached lifting eyelets in order to prevent inadmissible bending

stress due to their weight.

Fig. 70 - Loading of PKS® DN 2300 sewage pipe and DN 2300 branch section

Fig. 71 - Installation of PKS® special element

Fig. 72 - Unloading and installation of PKS® DN 1800 pipe

Fig. 73 - Unloading and positioning of PKS® DN 3000 pipe


Storage of DIN 8074/8075 PE pipes

PE pipes are supplied in bundles according to the AGRU-FRANK

GmbH factory standard for packaging. The bundles are shipped

on pallets. Small batches are supplied as loose pipes.

To load and unload the pipe bundles and individual pipes, use

wide textile straps and protect the pipes against mechanical

impact.

Before unloading the pipes, prepare the on-site storage area.

The storage area should meet the following requirements:

� Minimum width 12 m, 6 m or 5 m (depending on pipe length)

� Stone-free, level ground (sand bed, concrete slab, etc.)

� Protected against mechanical impact

� Installation of intermediate supports to prevent sagging or

shifting of the pipes

Pipe pallets must be stacked in such a way that the axial timber

crates are positioned one on top of the other.

The stack height must be chosen carefully to prevent perma-

nent deformation of the pipes. Prevent point and linear bearing

points of the pipes.

Protect all parts of the pipe against dirt.

Storage

PE/PP pipes must be stored on level ground. Do not place the pipes on stones or sharp-edged objects. The pipes must be stored

so that they cannot become deformed. Protect them against dirt and mechanical damage.

In warm weather, pipes and fittings must be protected against heat. We recommend storing the pipes and fittings in the shade or

under a light-reflective tarpaulin or foil. Many geotextiles are suitable for this purpose.

As a rule, the pipes must be protected against deformation and damage and handled with the necessary care during transporta-

tion and storage. Pipes that have been damaged must not be installed.

Storage of DIN 16961 / DIN EN 13476 spiral pipes

8. Installation

8.1 General installation guidelines

The pipes must be stored so that they cannot become dam-

aged. Ensure that the spigot ends and the sockets are pro-

tected against dirt and deformation, as they can otherwise not

be properly joined.

For temporary storage on the construction site, it might be

necessary to prepare the storage location, depending on the

ground and weather conditions:

� Pipes must be secured against rolling off by placing them on

squared timber sections and/or inserting wedges.

� The first layer of pipes must be placed on square timber

sections.

� Do not stack the pipes higher than 3 metres.

When storing pipes of different diameters together, ensure that

the electrofusion sockets and spigot ends of the PKS® pipes

are not damaged. If necessary, position the pipes so that these

sections protrude from the stack.

Before storing the pipes, check them carefully to ensure that

the original packaging is not damaged. Should the packaging

be damaged, check the respective pipe for dirt and clean it im-

mediately. Subsequently cover the cleaned sections with foil.

Do not apply adhesive foil or tape to the electrofusion wire or

the spigot end of the pipe.

Fig. 74 - Storage of PKS® sewage pipe Fig. 75 - Storage of Sureline® pipes


8.2 Trench installation - PKS®/TSC pipes

8. Installation

According to DIN EN 1610, a load carrying capacity certificate must be submitted for all underground sewage and drain pipes prior

to installation. For PKS® /TSC pipes, the calculation of the carrying capacity according to ATV-DVWK-AT 127 is deemed sufficient.

The pipes must be installed with reference to the static calculations. The information required for the static calculations (e.g. ground

conditions, installation conditions, etc.) must be obtained from the customer in a questionnaire (see pages 44 ff.).

Flexible pipes must be installed "loose", as this reduces the stress on the pipe. The static calculations must take into account the

bedding angle. Normally, a bedding angle of 120° is used in the calculations.

According to DIN EN 1610, the base bed must have a thickness of 10 to 15 cm from the bottom of the pipe. Only use stone-free,

compactable bedding material of class G1 or G2 as specified in DIN EN 1610. Bedding of the same material must then be filled to

a level 15 cm above the top of the pipe. The bedding material must be compacted in layers. Ensure that the compactor does not

touch the pipe. To compact the material above the pipe, do not use a compactor until the bedding thickness above the top of the

pipe is minimum 30 cm. The top fill material must also be filled and compacted in layers. Top fill layers of up to 1 metre depth can

be compacted with light to medium weight compactors. Heavy compactors may only be used above this level.

In the event of high temperature fluctuations, especially where the pipe is exposed to direct sunlight, it might expand or contract

in axial direction. In underground PKS® pipes, the profile acts as a fixed point. It is thus sufficient to fill the pipe trench in order to

prevent elongation along long stretches of the pipeline.

Recommendations

� The pipeline trench should be free of stones and the bedding

material must be compactable.

� Take suitable measures to prevent soil from falling into the

trench and ensure that the bedding material is not acciden-

tally spread into the ground surrounding the trench.

� The ground material on both sides of the pipe must be refilled

and compacted in layers. Where the sides around the pipe

have not been properly compacted and a heavy machine

is used for the compacting of the top layer, the pipe might

be shifted to the side. This might for example occur if a road

roller passes over a pipe without compacted side bedding.

� During pipe laying, the trenches must be kept free of water

in order to prevent floating pipe sections.

� When connecting flexible pipes (PKS® /PROFIX pipes) to a

concrete manhole, proceed with special care as the manhole

might shift due to soil settlement.

� Leakage tests must always be performed before the pipe

trenches are backfilled, as it is otherwise difficult to locate

and repair leaks.

Fig. 76 - Installation of pipeline section

Fig. 77 - Compacting of side bedding


8. Installation

Due to the surface structure of PE/PP, there is no direct connection between the PE pipes and the concrete used to connect them

to other fixed structures. There is a capillary gap between the pipe wall and the concrete through which liquid can escape and

enter the concrete wall. In order to integrate PE pipes into concrete walls, it is therefore necessary to use FRANK wall connection

elements, sockets for manhole connections and manhole connection sockets that have been specifically designed for this purpose.

FRANK wall connection type PKS® 2, type PKS® 2a

The FRANK type PKS® 2 and 2a wall connections are suitable for

PKS® sewage pipes of DN 300 to DN 1200. The type PKS® wall

connections are tight to a water column of 10 metres.

The length of the wall connection depends on the actual con-

crete wall thickness and must be custom-made (type PKS® 2

element). The FRANK type PKS® 2 and 2a wall connections are

installed into the concrete structure so that they are flush with

the formwork. The wall connections are equipped with a wire for

electrofusion welding. The wall connection can withstand high

radial and axial forces as they are transferred from the PKS® pipe

to the concrete structure.

8.2 Trench installation - connection to concrete elements

FRANK manhole connection socket (SAM)

The FRANK manhole connection socket (SAM) allows for the

production of welded connections between pressure pipes and

concrete manholes that offer excellent tensile strength. The

manhole connection sockets are available for extruded sewage

pipes from DN 150 to DN 500.

The manhole connection socket is installed in the precast con-

crete manholes conforming to DIN 4034 so that it is flush with

the formwork. The puddle flange mounted on the manhole

connection socket ensures that the connection is perfectly tight.

When concreting in the connection, ensure that the concrete is

sufficiently compacted. After the concrete work is completed

and formwork is removed, the pipe is inserted and welded to

the socket.

Electrofusion wire

FRANK puddle flange

Groove for high-strength anchoring

Stop defining the insertion depth of the PE pipe d

Fig. 78 - Installed FRANK manhole connection socket (SAM) Fig. 79 - Type PKS® 2 Fig. 80 - Type PKS® 2a

Fig. 81 - Installed FRANK manhole connection socket (SAM) Fig. 82 - FRANK type PKS® 2a wall connection (L= 140 mm)

140 mm200 - 300 mm


FRANK wall connection type PKS® 1

For DN 300 to DN 3500 pipes, we have developed the FRANK

type PKS® 1 wall connection with mounted FRANK puddle flange

for PKS® sewage pipes. The wall connection is tight up to a water

column of 10 metres The FRANK type PKS® 1 wall connection

is supplied fully fitted on the PKS® pipe. The pipe with the wall

connection element is placed in the formwork. We recommend

backfilling the pipe trench prior to concreting the wall connection.

Close the formwork and encase the connection in concrete.

Ensure that the concrete is properly compacted around the wall

connection, and in particular below the pipe. If the concreting

work must be performed at a temperature below 0°C, take the

necessary measures to ensure that the concrete meets the

relevant quality standards.

8. Installation

8.2 Trench installation - connection to concrete elements

Tightness certificate for FRANK type PKS® 1 wall connection

In May 2009, Institut für Unterirdische Infrastruktur GmbH (IKT),

a testing institute specialising in underground infrastructure pro-

jects based in Gelsenkirchen, Germany, was commissioned to

perform long-term tightness tests (1000 h) of FRANK type PKS®

1 wall connection, size DN 800.

The tests were performed with two wall connections consisting

of DN 800 spiral pipes and circular DN 1250 formwork encased

in waterproof concrete. Before the wall connections were made,

a perforated pressure water pipe was built into the DN 800 spiral

pipe. After the concrete had cured, a test pressure of 1.0 bar

was applied to the integrated pressure pipe.

This pressure was maintained over the entire test period of 1000

hours. During the leakage test, no testing liquid escaped from the

tested construction. The tested construction was then cut open

in order to identify the testing liquid flow inside the structure. The

visual inspection revealed that discoloured areas expanded from

the perforated pressure pipe to the plate flange. There were no

signs of any further penetration into the wall connection.

This test thus showed that the construction remained tight

during the test period of 1000 hours at a test pressure of 1.0

bar. The two tested wall connections successfully passed the

long-term test and provided perfectly tight connections to the

concrete structure.

(Source: IKT report published in 2009)

IKT - Institut für Unterirdische Infrastruktur

Exterbruch 1, 45886 Gelsenkirchen Telefon: 0209/17806-0 Telefax: 0209/17806-88

Bericht: P02890

Gelsenkirchen, 9. Oktober 2009

Auftraggeber: Frank GmbH

Starkenburgstraße 1

64546 Mörfelden-Walldorf

Prüfauftrag Nr.: P02890

Bezeichnung des Prüfauftrags: 1.000h-Langzeit-Dichtheitsprüfung einer zug-

festen Wandeinbindung DN 800 aus EPDM

mit Spannbändern aus Edelstahl und PEHD-

Plattenkragen (FRANK-Wandeinbindung)

Datum des Auftrages: 21.04.2009

Bezeichnung des Auftraggebers: -

Dieser Bericht besteht aus 9 Seiten

Die Prüfergebnisse beziehen sich ausschließlich auf die Prüfgegenstände. Der Prüfbericht

darf auszugsweise nur mit schriftlicher Genehmigung der IKT - Institut für Unterirdische

Infrastruktur gGmbH vervielfältigt werden.

Dipl.-Ing. D. Homann Dipl.-Ing. A. Redmann

(Leiter der Prüfstelle) (Projektleiter)

FRANK puddle flange

Plate flange

Fig. 83 - Type PKS® 1 - cross-section Fig. 84 - Type PKS® 1 at pipe end

Fig. 85 - IKT report - Leakage testing of high-strength FRANK wall connection


8. Installation

8.3 Trenchless installation

Introduction

In Germany, many existing sewage pipe systems are leaking or do not have the load-bearing capacity required today. In many

cases, the pipes can be restored by means of relining, where a new pipe is inserted into the defective pipeline. Extruded solid wall

pipes and PKS® pipes with integrated electrofusion sockets are particularly suitable for repairs by relining. The electrofusion sock-

ets can withstand high tensile stress while the flexibility of the material used in solid wall and PKS® pipes allows for bending radii of

up to 50 x DN. In PKS® pipes with outside profiles, the profile provides the anchoring structure for the insulating filler, preventing

longitudinal expansion due to temperature differences.

Plastic pipes can be produced for use as non-load-bearing liners for insertion into existing pipelines or as load-bearing sewage

pipes for new installations. When installing insulation, the fact that this material produces buckling pressure on the pipe must be

taken into account and the pipes must be dimensioned accordingly. It might even be necessary to fill the pipes with water prior

to installing the insulation. In addition, the possibility that the pipes might become buoyant during the insulation process must be

taken into account. On request, we perform certifiable static calculations according to DWA-M 127-2. In practice, the following

relining methods are used:

Pipe string relining (long pipe relining)

For this purpose a number of pipes are welded together to form

a string, which is then pulled or pushed into the sewage pipe.

Pipe strings of up to 500 m can be pre-assembled outside the

system section to be repaired. Pipes from DN 800 can be indi-

vidually placed in the pipeline to be repaired and then welded

from the inside.

Short pipe relining

Here, the pipes are pushed or welded together in a manhole.

After a weld is completed, the pipe string is pulled into the sew-

age pipe to be repaired so that the next section can be lowered

into the manhole and connected. For this type of renovation,

FRANK provides pipes of 1 to 6 m length as well as PKS® pipes

with moulded electrofusion sockets.

Ploughing

Using a special plough, a slit is cut into the ground. Special plough

attachments push the soil outwards so that a pre-assembled

pipeline can be installed in the same process. The space around

the pipe can then be filled with sand or fine backfill material mixed

with water to allow for additional compaction. As there is no

pressure on the pipe from the overlaying topsoil, the pipeline is

properly stabilised in the ground.

Milling

With this method, a pipe trench is cut using special milling equip-

ment, and the pre-assembled, flexible pipe is installed in the

same process. The excavated material is then used for back-

filling. Milling is only suitable for pipe installation in free terrains.

Installation with drilling rockets/burst lining

The burst lining method is used to replace existing pipelines

by laying a new pipe in the same trench. This is done by using

dynamic or static energy. The cone-shaped bursting body de-

stroys the old pipe and pushes out the adjacent trench material

to form a circular cavity. The new pipe is pulled into this cavity

immediately following the bursting process, whereby the new

pipe is of the same or a greater diameter (up to DN 600).

Hydraulic drilling (horizontal)

Drill heads for hydraulic drilling include a cutting tool and openings

through which a betonite mixture is expelled at high pressure.

The drill head is steered by the pressure of the betonite suspen-

sion through a programmable interface at the drill head. After

the pilot drill bore is produced, an expansion head is attached

together with the pipe, which is then pulled through the opening.

Fig. 86 - Short pipe relining Fig. 87 - Horizontal hydraulic drilling Fig. 88 - Burst lining


daPipe

max. permissible tensile stress [kN] for Sureline®

[mm] SDR 17 [kN] SDR 11 [kN]

110 21 (14) 31 (21)

125 27 (18) 40 (28)

140 34 (23) 50 (35)

160 44 (30) 66 (46)

180 56 (39) 84 (58)

200 70 (49) 103 (72)

225 89 (62) 131 (91)

250 109 (76) 162 (113)

280 137 (95) 203 (142)

315 174 (121) 257 (179)

355 221 (153) 326 (228)

400 280 (195) 414 (289)

For insertion times > 10h (> 20h), reduce the

specified values by 10 % (25 %).

daPipe Bending radius r [m]

d [mm] at +20°C at +10°C at 0°C

110 2.2 3.8 5.5

125 2.5 4.3 6.2

140 2.8 4.9 7.0

160 3.2 5.6 8.0

180 3.6 6.3 9.0

200 4.0 7.0 10.0

225 4.5 7.8 11.2

250 5.0 8.7 12.5

280 5.6 9.8 14.0

315 6.3 11.0 15.7

355 7.1 12.4 17.7

400 8.0 14.0 20.0

8. Installation

8.3 Trenchless installation

Advantages of Sureline® pipes in trenchless installation

The forces acting on a pipe during trenchless installation differ greatly from those during open trench laying. Trenchless methods

demand sturdy pipes. When pulling a burst lining into the existing pipe or during horizontal hydraulic drilling, the outer surface of the

pipe becomes normally scratched, and the resulting grooves might compromise the stress distribution in the pipe wall. Point loads,

e.g. from stones, can result in additional local stress on the inside of the pipe. In pipes made from conventional materials, this tends

to result in crack initiation. To prevent that such stress results in cracks in the pipe wall, it is important to use a pipe material, such

as FRANK PE 100-RC, that offer excellent creep resistance. Due to their high elasticity, Sureline® pipes are particularly suitable for

installation along curved trenches, as the material can be bent to a certain degree. However, the minimum bending radii listed in

the table below must be taken into account.

Fig. 89 - Stress on pipe in trench

During trenchless pipe laying (e.g. by horizontal hydraulic drilling),

certain tensile stress levels must not be exceeded (see DVGW

GW 320 work sheet). The table below provides an overview of

the maximum permissible tensile stress for the installation of

Sureline® pipes at 20°C (40°C).

Bending radii for Sureline® pipes

Fig. 90 - Bending radii achievable with different pipe systems

By making use of the flexibility of Sureline® pipes, sewage system

operators can save money, as fewer fittings are required than

with conventional pipes. The diagram below shows the minimum

bending radii for various pipe dimensions.

traffic load

soil load soil load

traffic load

hydrostatic inside pressure, hydraulic shock

highest stress concentration

point loads

bending radiuses [m]

steel cast iron PVC

Table 7 - Max. permissible tensile stress for Sureline® pipes Table 8 - Permissible bending radius for Sureline® pipes


According to DIN EN 1610, a leakage test of the installed plastic pipe must be performed after backfilling and removal of the instal-

lation equipment. The leakage test according to DIN EN 1610 is described in detail in DWA-A 139 and can be performed with water

or with air (methods "W" and "L" respectively).

A preliminary test might be performed prior to backfilling, and such a test is recommended for the testing of pipe joints. By per-

forming the leakage test immediately after installation of the pipe, it is possible to detect any problems at an early stage so that

they can be rectified without delay. This saves money as the machinery and personnel are likely to be still on site to carry out the

necessary tasks.

8. Installation

8.4 Leakage test for gravity pipelines

Leakage test with water (method "W")

The requirements for this leakage testing method are not de-

scribed in detail, as they are specified in the above standard.

The testing process must be coordinated with the sewage

system operator.

p0 [kPa]

max ∆ p [kPa]

Testing time [min]

Pipe diameter [DN] 100 150 200 250 300 400 500 600 700 800 900 1000

Air overpressure LE LF

10 20

1.51.5

1.5+1.0

2.51.5

3.02.0

4.03.0

4.53.0

6.04.0

7.55.0

9.06.0

10.57.0

12.08.0

13.59.0

15.010.0

Underpressure LEu LFu

-10-20

1.11.1

1.51.0

2.51.5

3.02.0

4.02.5

4.53.0

6.04.0

7.55.0

9.06.0

10.57.0

12.08.0

13.59.0

15.010.0

Fig. 91 - Socket pressure tester for gravity pipelines

Leakage testing with air (method "L")

The connections can be tested for leakage, using a socket pres-

sure tester. Before performing this test, the testing equipment

must be tested to ensure that it is air-tight. This can be done by

performing a leakage test of a tight pipe section, whereby all

results must be carefully documented.

The leakage test with a pneumatic socket pressure tester is

performed separately at each pipe weld.

Before starting the test, the welded joints must be allowed to

cool down (recommended cooling time: minimum 3 hours).

The socket pressure tester is positioned at the welded connec-

tion to the tested. An initial pressure (testing pressure + approx.

10 %) is applied to the pipe, followed by a settling time of approx.

5 minutes. Subsequently, the connection can be tested (for

testing times, see table 10).

If the section to be tested is within the groundwater area, the

highest groundwater level must be taken into account by in-

creasing the testing pressure by 1 kPa per 10 cm of ground

water above the bottom of the pipe.

For occupational safety reasons, we recommend applying test

pressures that are within the prescribed range for method "LE"

Method LE/LEu: t = 0.015 x DN [min]

Method LF/LFu: t = 0.01 x DN [min]

Testing times for pipe diameter other than those listed in the

table are calculated as follows:

The testing time is rounded to the next 30 seconds.

Table 9 - Testing conditions for gravity pipelines according to DWA-A 139

for all pipes with DN > 1000.

If the permissible testing criteria (max ∆ p) cannot be achieved,

the pipe section must be tested with method "W" (leakage test-

ing with water). In this case, the result of the leakage test with

water is the only relevant test result.


8. Installation

8.5 Leakage test for pressure pipelines

Table 10 - Contraction procedure for pressure drop testing method example of testing conditions for PE 100, SDR 17 pressure pipe according to DVGW W 400-2

Contraction procedure - pressure drop method

Material PE 100, D 355, SDR 17

Testing pressure [bar] 12.0

Testing time [h]

160 minutes

Pressure drop[bar] pab = 2.0 bar within 2 minutes

Extracted volume of water ∆Vzul

[ml/m]within 2 min; ∆Vzul = 192.81 ml/m

Evaluation of air tightness measured Vab (at pab) ≤ Vzul

Testing time 30 minutes

∆pzul [bar] 0.25 bar after 90 minutes

Criterion for tightness: The pressure values measured over the testing time must be constant or show a slight

upward trend.

Pre

limin

ary

test

Pre

ssure

dro

p t

est

Main

pre

ssure

test

Today, pressure pipes are normally tested for leakage by means

of the contraction method.

Contraction procedure according to DVGW W 400-2

This procedure consists of a preliminary test and a main test.

The preliminary test is performed to stabilise the pipeline sec-

tion to be tested. It must ensure that the preconditions for a

standardised and reproducible measurement of the volumetric

change over time, relative to the internal pressure and tempera-

ture, are met.

Contraction testing procedure

Preliminary test phase:

After filling and bleeding the pipeline, the section to be tested

must not be pressurised for a period of 60 minutes (settling

phase).

Subsequently, the design system pressure STP is built up. This

should preferably be completed within 10 minutes (for PE 100,

SDR 17 the design system pressure STP = 12.0 bar).

The design system pressure STP is then maintained for 30 min-

utes by continuous pumping of water into the pipe.

Subsequently, pumping must stop and the pipe must be left

filled for a period of 60 minutes. During this phase, the pres-

sure pipe undergoes visco-elastic deformation. The resulting

pressure drop must however not exceed 20 %. If the pressure

drops by more than 20 % of the design system pressure STP,

there is a leak in the pipe or the pipeline is exposed to excessive

temperature differences.

Main test phase:

The pressure must be rapidly reduced by pab specified in table

11. The pressure drop must be achieved within maximum 2 min-

utes. The volume Vab of the water expelled during this process is

measured (pressure drop test). Compare the calculated change

in volume with the actual measured change in volume ∆Vg. The

pipe is sufficiently air-free, if the released volume of water Vab is

smaller than the calculated volume Vzul.

Subsequently, the pipe must be tested for another 30 minutes

(testing time tk). The pipe section is deemed tight, if the pressure

measured during the above contraction time of 30 minutes is

constant or shows a slight upward trend.

If the results are inconclusive, the testing time tk might be ex-

tended to 90 minutes. During this period, the pressure must

not drop by more than 0.25 bar, relative to the highest value

measured during the testing time.

All pressure measurements taken over the entire test procedure

must be carefully documented.

Vzul = Vk x L

Pressure drop [bar]

PE 100 SDR 17 2.0 [bar]

PE 100 SDR 11 3.2 [bar]

Table 11 - Pressure drop

STP ... System testing pressure [bar]

pab ... Pressure drop [bar]

Vg ... Calculated volume of water [ml/m]

Vab ... Volume drop [ml]

Vzul ... Max. permissible volume of water [ml]

∆pzul ... Permissible pressure drop [bar]

Vg ... Measured volume of water [m3]

tk ... Testing time [h]

L ... Length of pipeline [m]

Vab ≤ Vzul


9.1 Overview of welding methods


General welding instructions

� Protect the welding area against adverse weather conditions (e.g. precipitation, wind, direct sunlight, temperatures < 5°C). If

it is possible to take suitable measures (e.g. preheating, erecting a tent) to ensure that the pipe wall temperature required for

welding is maintained, welding work can be carried out at any outdoor temperature, provided that the welder is not hampered

in his work by the adverse conditions. If required, produce sample seams under the expected conditions to determine whether

welding is possible.

� If certain sections of the pipe surface are heated by direct sunlight while others remain cool, cover the welding area to ensure

a uniform temperature across the relevant pipe section.

� All connections must be established while there is no stress on the pipes, irrespective of the chosen welding method.

� The connecting faces of the parts to be welded must be perfectly clean. Clean the connecting faces just before welding, using

a special PE cleaner. Cleaning is extremely important and must be carried out with special care. Dirt and moisture can interfere

with the welding process, preventing accurate and tight welding. If the welding faces have not been properly cleaned, the

connection might leak at a later stage!

� All tools required for welding such as tension bands, clamping and tensioning tools, etc. must only be operated by trained and

qualified personnel.

� The instructions of the German Welding Society DVS must be adhered during the entire welding process.

Electrofusion welding of DIN 16961 / DIN EN

13476 spiral pipes

Extrusion welding Electrofusion welding of DIN 8074/8057 extruded

sewage pipes

Butt welding of DIN 8074/8075 extruded

sewage pipes

DVS 2207-1 Technical Code DVS 2207-4 Technical Code DVS 2207-1 Technical Code DVS 2207-1 Technical Code

� PKS® profi led sewage

pipes of sizes DN 300 to

DN 2400 are connected

by means of electrofusion

welding according to DVS

2207.

� The resistance wires are

integrated into the sock-

ets of the PKS pipes.

� This welding technique

has been proven par-

ticularly suitable for pipes

made in polyethylene

used in sewage systems

and has become stand-

ard practice.

� Electrofusion welds can

be easily produced on

site.

� For pipe sizes that are

not suitable for electrofu-

sion welding and for the

installation of manholes,

bends and other fittings,

the pipes are connected

by means of extrusion


2207-4.

� This method allows for

customised construc-

tions.

� The parts are welded by

continuous welding us-

ing a welding extruder.

For larger connections,

it is recommended to

use an automatic welding

machine.

� For smooth extruded

sewage pipes and Sure-

l ine® pipes, addit ional

electrofusion fittings are

used to connect pipes

with nominal diameters

of d 160 to d 630. In this

case, the resistance wires

are integrated into the

electrofusion fittings (e.g.

welding sockets).

� The welding sockets

made in polyethylene are

produced in a modular

production process. This

method ensures that the

electrofusion wire is fully

embedded in the fitting.

� Extruded sewage pipes

and fittings made in PE

100 can also be con-

nected by means of butt


2207-1.

� The machines and equip-

ment used in this process

must however conform to

DVS 2208.

� With the butt welding

method, the prepared

joint areas are prepared

under pressure for proper

fit on the heating ele-

ment and subsequently

heated at reduced fitting

pressure. Subsequently,

the heating element is

removed and the pipes

are joined together under

pressure.



Introduction

At the construction site, the individual pipe sections must be

connected to each other. While these joints must be perfectly

tight, they must be easy to produce at reasonable cost. Tight

connections are obviously a prerequisite for tight sewage pipe

systems. The welding methods available for the joining of PKS®

profiled sewage pipes meet these requirements.

Electrofusion welding has for many years been used for the join-

ing of sewage pipes made in polyethylene. The method is also

been successfully used for the joining of polypropylene pipes.

With electrofusion welding, the pipes and fittings are heated by

resistance wires and subsequently fused together. The resist-

ance wires are integrated into the sockets of the PKS® pipes.

Where smooth sewage pipes are to be joined, these wires are

built into the electrofusion fitting.

The energy required for the process is produced by a welding

transformer. The relevant welding parameters are normally set

by scanning the barcode applied to the pipe or the fitting.

Only identical materials can be welded together with this method.

By heating the socket, a preset shrinking stress is produced,

which ensures that the pressure required for welding is applied.

The method is extremely safe, as safety low voltage is applied

to the socket or fitting, and most processes are automated. In

addition, the welding time is relatively short. This allows not only

for fast installation but also saves money.

Electrofusion socket

Homogene-ouswelding zone

Spigot end

Advantages of electrofusion welding

� Automated welding by means of automatic welding

machine

� Homogeneous welded connection, no inside welding

bead

� Perfectly tight welded connection

of great tensile strength, preventing

infiltration/exfiltration

� Quick connection, saving costs

� Easy pipe welding under site conditions

� Suitable for DN 150 to DN 2400

9.2 Electrofusion welding of DIN 16961 / DIN EN 13476 spiral pipes

Fig. 92 - Diagram of electrofusion weld in a socket

Dimensions[mm]

Preparation time

~[min]

Welding time (20°C)

[min]

Cooling time[min]

DN 300 10 12 40

DN 400 10 13 40

DN 500 10 15 40

DN 600 10 15 40

DN 700 10 19 40

DN 800 15 15 40

DN 900 15 15 40

DN 1000 15 17 40

DN 1100 15 18 40

DN 1200 15 20 40

DN 1300 15 20 40

DN 1400 15 20 40

DN 1500 15 20 40

DN 1600 15 20 40

DN 1800 15 20 40

DN 2000 15 20 40

DN 2300* 15 25 40

DN 2400* 15 25 40

Processing times for PKS sewage pipes

Table 12 - Processing times

* Observe preheating time! After welding, wait for minimum 3 hours before performing a leakage test

Who is entitled to weld pipes?

All welding work must be performed by persons who have been

specially trained in this task and who are certified for the respec-

tive welding technique.

For electrofusion welding of PKS® pipes, FRANK GmbH offers

training and instructions for welding staff on request.

Also ensure that only machinery that meets the applicable DVS

requirements is used.

The welding data must be documented in welding reports or

in electronic format.



9.3 Electrofusion welding following DVS 2207-1, process description for DIN 16961 / DIN EN 13476 profiled sewage pipes

1. Introduction

� PKS® pipes for electrofusion welding are supplied with spigot ends

and integrated electrofusion wires in the sockets. To protect the

welding ends during transport and on the building site, they are

covered with a protective foil. The protective foil must only be

removed immediately prior to the cleaning and joining of the elec-

trofusion socket with the spigot end.

� From DN 800, the spigot end must be supported with a special

support ring to allow for a higher joining pressure. Only use FRANK

support rings, tension bands and clamping tools. For wall connec-

tions and sockets for manhole connections, always use a support

ring, irrespective of the pipe diameter.

� From DN 1400, the pipes are equipped with two electrofusion

wires per socket, so that two welding machines are required to

produce the connection.

� After preheating (from DN 2300), wait for 10 minutes before start-

ing the welding process.

� Ensure that the power supply on site provides minimum 15 kVA

at all times.

� All instructions for the welding and joining of PKS®pipes with inte-

grated electrofusion socket apply.

� For staff who perform this task for the first time, FRANK GmbH

offers training covering the detailed welding standard as well as

all special features and work practices associated with the laying

of PKS® pipes.

2. Preparation

� Clean the pipe ends with a hand brush. Check the electrofusion

socket and the spigot end for damage caused during transport

or storage.

� Position the pipes so that the connecting points of the wires are

easily accessible.

� Remove the protective foil and clean the electrofusion socket/

spigot end with a PE cleaner, using a lint-free, white paper tissue.

� Using a permanent felt-tip pen, mark the available/measured

socket depth at the spigot end. Mark the depth at minimum 3

separate points that are equally spaced along the circumference.

The pipes must be pushed together to the marks or to the stop

(ensure that the pipes are straight and pushed together with equal

force around the circumference). For large pipes or where the site

conditions make it difficult to align the pipes correctly or push them

together, use a tensioning device (tension straps). Ensure that no

dirt or water can enter the gap between the electrofusion socket

and the spigot end.

Fig. 97 - Positioning of welding ring

Fig. 98 - Connection of separate electrofusion wires (from DN 1400)

Fig. 99 - Cleaning the electrofusion socket and the spigot end

Fig. 100 - Marking the insertion depth


Fig. 97 - Positioning of welding ring

Fig. 98 - Connection of separate electrofusion wires (from DN 1400)

Fig. 99 - Cleaning the electrofusion socket and the spigot end



9.3 Electrofusion welding following DVS 2207-1, work description for DIN 16961 / DIN EN 13476 profiled sewage pipes

3. Welding of pipes

� After the pipes to be welded have been pushed into each other,

mount the support ring (from DN 800). Then attach the tension

band in the groove of the electrofusion socket and tighten it with

the clamping tool (positioned at an offset of minimum 250 mm

from the connecting wires) until the gap between the electrofusion

socket and the spigot end is closed along the entire circumference.

� Connect the wires of the electrofusion socket through the PKS®

adapter to the PKS® welding machine. When connecting the wires

to the welding machine, ensure that the welding cables are not

stressed.

� After entering the welding data or scanning it with the hand-held

barcode reading pen, the process can be started at the welding

machine. The welding machine thereby automatically controls

and monitors the welding process across the entire welding time.

If there are any deviations from the set welding parameters, the

welding machine automatically aborts the welding process, and

an error message is displayed on the device.

� After 2/3 of the welding time has elapsed, and at the end of the welding process, the tension band must be re-tightened.

� During the cooling time of minimum 40 minutes, the pipe must not

be moved under any circumstances.

� After the cooling time has elapsed, remove the tension band and

the support ring. The welding connection is now completed and

is ready for operation under full load.

� To document the installation, mark the welding point with the wire

number, the name of the welder, and the date and time of welding.

� After the welding process is completed, the connection must be

tested for leakage according to DIN EN 1610. From DN 700, this

might be done with a pneumatic socket pressure tester or similar

device. Before side filling the trench, or before pulling the pipe into

a cladding pipe, you must perform a preliminary leakage test (see

DIN EN 1610, section 10).

Fig. 101 - Pulling the pipes together

Fig. 102 - Tightening of tension bands

Fig. 103 - PKS® welding adapterFig. 104 - Connection for welding cable

Fig. 105 - Scanning welding codeFig. 106 - Socket pressure tester


9.4 Extrusion welding according to DVS 2207-4, process description for DIN 16961 / DIN EN 13476 profiled sewage pipes


Fig. 107 - Welding extruder

Fig. 108 - FRANK welding robot

Fig. 109 - Weld seams

Fig. 110 - Extrusion seam/welding seam

1. Introduction

� Extrusion welds in PKS® pipe systems of any size are produced

according to DVS 2207-4 by means of continuous welding. The

pipes are supplied with prepared sockets and spigot ends.

� From DN 800, the pipes must be welded at both the inside and

outside. Up to size DN 800, welding from the outside is generally

sufficient for normal operating conditions.

� When welding from the inside, the spigot end must be equipped

with a welding groove according to DVS 2207-4. The socket end

is bevelled. For extrusion welding from the outside, it is not neces-

sary to prepare the joint as described above.

FRANK welding robot

� Apart from conventional welding techniques with welding extrud-

ers, it is also possible to join the pipes using a welding robot. The

FRANK welding robot allows for fast and cost-efficient installation

of the pipes.

2. Welding of pipes

� After the pipe ends have been cleaned and the pipes have been

pushed together, machine the pipe faces in the welding area.

� To produce a continuous extrusion weld according to DVS 2207-

4, use a welding extruder with a welding shoe that matches the

weld geometry.

� If necessary, first tack the spigot end and the socket together by

hot gas welding.

� After the welding process is completed, mark the weld with a

permanent felt-tip pen (wire number, date and name of welder).

� At low ambient temperatures, cover the weld area to prevent it

from cooling too quickly.

� Remove the flashing that might appear under the welding shoe

surfaces without causing any notches.

� After the weld has cooled, perform a leakage test, for example

with a socket pressure tester.


9.5 Electrofusion welding according to DVS 2207-1, process description for extruded DIN 8074/8075 pipes


Note:

When sliding the pipes into the socket, ensure that they are not jammed.

Do not attempt to drive in the pipe ends by force, for example with a

hammer or mallet. If the pipes ends are no longer perfectly round so that

they cannot be easily pushed together, use rounding clamps. Do not at-

tempt to cut the pipe to fit with a hand scraper or similar tool.

Note:

It is not possible to weld the pipes correctly without

first machining the welding area!

1. Introduction

� To join extruded pipes by means of electrofusion welding, the fit-

tings and pipes are heated and welded by means of resistance

wires, similar to the process for PKS sewage pipe systems.

� Only identical materials can be welded together by this method. The

instructions of the German Welding Society DVS must be adhered

during the entire welding process.

� All welds must be produced with welding machines (e.g. FRANK

polycontrol plus) that have been designed for this task.

� Protect the work area against direct sunlight and moisture. If neces-

sary, erect a welding tent (umbrella).Fig. 111 - Welding time

Fig. 112 - Cutting pipe to size

Fig. 113 - Marking pipe

Fig. 114 - Machining pipe surface

2. Preparation

� Install the welding machine and check the welding equipment. Cut

the pipe ends at right angles, using a suitable cutting tool, and de-

burr the outside edge. If the pipes ends are sagging, cut them off.

� Mark the insertion depth (insertion depth = 1/2 socket length). Clean

the insertion section with a clean cloth. Peel off the oxide layer

along the entire circumference to expose the insertion depth, using

a hand scraper or preferably rotational scrapers. Chip thickness:

approx. 0.2 mm. Remove the chips without scraping the prepared

pipe surface. Prepare the electrofusion fittings in the same manner.

� Just before producing the welded connection, remove the elec-

trofusion socket from the packaging. Do not touch the inside of

the socket or the prepared pipe surfaces with your fingers and

prevent any contamination by dirt.

� If this is not possible, clean the welding faces with an approved PE/

PP cleaner1) and a clean, lint-free, white paper tissue.

� Slide the electrofusion socket onto the pipe end to the centre stop

or the marked insertion depth. Insert the other pipe end to the

centre stop or the marked insertion depth.

� Check the insertion depth.



9.5 Electrofusion welding according to DVS 2207-1, process description for extruded DIN 8074/8075 pipes

3. Welding of pipes

� Secure the joint to be welded with clamps. Ensure that the wire

connections face upwards and that the pipes are positioned so

that they are not stressed during welding.

� Connect the welding cables, using suitable connectors. Ensure

that the welding cables are not stressed. Observe the operating

instructions for the welding machine!

� The welding machine indicates that contact is established.

Scan in the welding parameters, using the reading pen or

scanner. Check the information on the display (manufacturer,

diameter, etc.). If the details are correct, press the start button.

� Start the welding process at the device. Check the information on

the display (e.g. set welding time, actual welding time).

� The clamp/tension straps must remain mounted during the entire

welding and cooling time.

� An audible signal from the machine indicates that the welding time

has elapsed.

� Do not remove the clamp/tension strap at this point but wait until

the cooling time has elapsed. Allow the pipe to cool down properly!

� If welding is aborted during the welding time (e.g. due to a power

failure), it is not permissible to use the same socket again for the

joining of smooth extruded pipes!

� All welding parameters of the joint are stored in the automatic weld-

ing machine (e.g. FRANK polycontrol plus). This information can be

printed out later in the form of a welding report. If your machine

does not produce such reports, you must document the weld on

site, using a paper form.

� Indicators inform you of the progress and successful completion

of the welding process.

� The pressure test must only be performed after all welded con-

nections are fully cooled (normally approx. 1 hour after completion

of the last weld). The pressure test must be performed according

to the relevant standards (e.g. DVS 2210-1, EN 805, page T-59).

� For recommended welding equipment and tools, please refer to

our latest price list.

Note:

When using a FRANK electrofusion welding machine, you are now prompted

to confirm whether the pipes have been prepared and aligned. If this is the

case, press the green button!

Option:

Our electrofusion sockets are equipped with a traceability code (yellow).

Depending on the features of your welding machine, this code can be read

in order to document the component details.

Check:

Should a mark be at a distance from the socket end,

the pipe end is not correctly centred or pushed to

the stop in the socket. Realign the pipes and secure

them again in the correct position. The marks must

be visible right at the edge of the socket.

Fig. 115 - Checking insertion depth

Fig. 116 - Aligning the pipes

Fig. 117 - Connecting the welding machine

Fig. 118 - Scanning welding code


9.6 Butt welding according to DVS 2207-1, process description for extruded DIN 8074/8075 pipes


1. Introduction

� Butt welds must be produced by means of a suitable welding

machine. The connecting faces of the parts to be welded (pipes

or fittings) are prepared under pressure at the heating element.

The parts to be joined and subsequently heated at reduced pres-

sure are pushed together with force after the heating element has

been removed.

� The machines and equipment used in this process must conform

to DVS 2208-1. Always follow applicable DVS welding instructions

(e.g. DVS 2207-1).

� The mating faces of the parts to be welded must be free of dirt or

grease and must not be damaged in any way.

2. Preparation

� Position the welding machine, prepare and attach the accessories

and check the welding equipment.

� If the welding site needs to be protected against the elements,

erect a welding tent (umbrella).

� To prevent the pipe from cooling too quickly, for example due to a

draught inside the pipe, seal the open pipe ends.

� Before commencing the welding process, check the temperature

of the heating element and/or adjust it at the device (do not start

welding earlier than 10 minutes before the welding temperature

is reached).

� To protect the heating element against dirt and damage, it must

be stored in a protective bag. Only remove it from the bag just

before starting welding and place it in the bag again immediately

after welding is completed.

� Prior to each welding process, clean the heating element with a

clean, lint-free paper tissue.

� Clean the weld faces of the pipes with PE cleaner and a lint-free,

white paper tissue. Ensure that the welding faces are free of any

dirt particles!

� Before clamping the parts in the welding machine, align the pipes

and fittings in axial direction so that the surfaces are parallel to

each other.

� Ensure that the parts to be welded can be moved easily in axial

direction. To do this, you might need to install roller stands.

Fig. 119 - Butt welding machine

Fig. 120 - Protection against the elements - welding tent

Fig. 121 - Cleaning welding faces


9.6 Butt welding according to DVS 2207-1, process description for extruded DIN 8074/8075 pipes


3. Welding of pipes

� Plane the pipe ends at both sides and remove the chips from the

welding zone (with a paint brush, paper, tissue, etc.). Check the

welding faces to ensure that the planes are parallel by pushing the

parts to be joined together.

� In this process, also check the pipe offset. The rated wall thickness

of the parts in the joining area must be the same.

� Determine and set the required welding parameters at the welding

machine. Measure the movement pressure at the welding point

and add it to the alignment/joining pressure. The tool movement

pressure is measured while the welded parts are slowly moved

against each other. This pressure might be greater than the join-

ing pressure.

� The welding process is performed by applying the necessary

alignment pressure. The alignment pressure must be maintained

constant until the mating faces are fully flush with the heating ele-

ment. This step is completed when there is a visible bead along

the entire circumference of the welded parts.

� Reduce the set pressure to p ≤ 0,01 N/mm² and heat the pipe for

the time specified in the table of standard values. Mount the slide

to remove the heating element and join the welding faces (work

speedily to keep the changeover time to a minimum!).

� Gradually increase the joining pressure to the required value.

The joining pressure must be maintained until the weld has

cooled (forced cooling with coolant is not permitted!). After the

required cooling time has elapsed, remove the clamping tools.

� Perform a pressure test of the weld (normally about 1 hour after

the last weld has been produced). The pressure test must be

performed according to the relevant standards (e.g. DVS 2210-1,

Supplement 2, DIN EN 805, page T-59).

Fig. 122 - Checking pipe end offset

Inspection and reworking of welded joint

After joining the pipes, a continuous bead must be visible along the entire

pipe circumference. This bead should meet the following requirements:

� Uniform bead width and height

� Smooth bead surface

If beads are not of uniform appearance, this might be due to differences in

the melting properties of the joined materials. If a bead needs to be removed,

it must be cut or peeled off without leaving notches behind. Fig. 123 - Mounting heating element

Fig. 124 - Joining pipe ends

max. 10 %

Fig. 125 - Planing pipe ends



9.7 House connections

Advantages of PE T-pieces

� Compact design, ready for installation

and connection to conventional PVC/

standard sewage pipe

� Easy installation from the outside by

means of clamping tool

� Welding current applied through easily

accessible plugs

� Improved safety thanks to mechanical

interlocking

� Suitable for DN 300 to DN 3500

Fig. 126 - PKS® DN 150 house connection saddle

Fig. 127 - Clamping/welding

2. Welding of pipes

� Determine the pipe connecting point and cut an opening that is at

right angles to the pipe axis, using a hole saw.

� Deburr the opening and remove the oxide layer around the welding

zone with a hand scraper.

� Clean the prepared welding faces with PE cleaner and a lint-free,

white paper tissue. The welding faces must be perfectly clean

and dry.

� Slide the house connection saddle from the top onto the clamping

tool and lock it in position and clamp it. Slide the clamping tool to

the opening in the pipe and hook the threaded rod in the clamping

tool. Pull the saddle with the clamping tool outwards so that the

collar of the saddle touches the inside wall of the PKS pipe.

� Align the saddle and secure it with the wing bolt.

� Slide the welding adapter by 4.0 mm onto the contacts of the sad-

dle and connect the welding machine. Scan in the welding code

and start the welding process. Observe the cooling instructions

of the manufacturer.

1. Introduction

� If a house needs to be connected to an existing sewage pipe

system, a T-fitting must installed at the PKS® pipe.

� In DN 300 to DN 3500 pipes, the house connection saddle can

be welded. The smooth 90° PE T-piece (DN 150, d 160 x 9.1 mm)

allows you to produce connections of any type, for example by

using FRANK electrofusion fittings for PE pipes or conventional

plastic fittings to fit PVC/standard sewage pipes.

� The PE T-piece can be mounted from the outside. The house

connection is simply pushed with a special clamping tool into the

outlet opening cut with a hole saw so that it is at right angles to

the profiled sewage pipe axis. It is then permanently clamped to

the pipe. The PE T-piece is then welded to the inside surface of

the profiled sewage pipe by means of electrofusion with a FRANK

welding machine through the plugs attached to the clamping tool.

Apart from homogeneous welds produced with spiral electrofu-

sion wires with integrated PE core, the connection is mechanically

interlocked for greater tensile strength.

� The house connection saddle designed for new installation and

renovation in open trenches is of a compact design and ready for

installation by welding on site.

� Always observe the installation instructions of the manufacturer!


9.8 Plug-in connections - TSC-Pipe


Fig. 128 - Cleaning the spigot end


Fig. 130 - Cleaning the socket

Fig. 131 - Applying lubricant

2. Connecting pipes

� Position the pipes so that the pipe ends are easily accessible. Check

the socket and spigot end for damage caused during transport

and storage and clean them.

� Mark the insertion depth (min. 125 mm) on the spigot end, using

a permanent felt-tip pen. Mark the depth at a number of separate

points that are equally spaced along the circumference.

� Slide the sealing rings onto the cleaned spigot end and position

them in the grooves.

� After mounting the sealing rings, treat the socket with the supplied

lubricant. Do not apply lubricant to the spigot end.

� Push the pipes together to the marked insertion depth. Make

sure that the pipes are correctly aligned to each other to prevent

jamming.

� The connection must be tested for leakage according to DIN EN

1610 (e.g. with a pneumatic pressure tester). Before side filling the

trench, or before pulling the pipe into a cladding pipe, you must

perform a preliminary leakage test.

1. Introduction

� TSC-Pipe is a pipe system with plug-in connections. The profiled

spiral pipes and matching fittings are equipped with spigots and

sockets, similar to the PKS sewage pipes.

� In TSC-Pipe, the socket is however not equipped with an elec-

trofusion wire. The PROFIX spigot end features 2 grooves for the

installation of 2 EPDM sealing rings. This integrated, locking double

lip seal prevents infiltration and exfiltration of the rain water.

� To prevent damage to the sealing rings, these are supplied sepa-

rate from the pipes.

� The pipes must be installed according to the applicable standards

and regulations (see chapter 8.2). Always follow the instructions in

the general installation guidelines (chapter 8.1).

� On site, pipes and fittings must be stored in such a way that the

sockets and spigot ends are protected against impact and dirt.


9.9 Detachable connections - flange connections


Fig. 132 - PE welding stub Fig. 133 - PE backing ring Fig. 134 - Flange connections in sewage treatment plant

Fig. 135 - Flange connection to PKS® pipe

2. Connecting pipes

Aligning parts

� Before inserting the bolts, the sealing faces must be aligned so that

they are flush and tightly packed against the seal. Do not attempt

to align the flange connection by tightening the bolts, as this would

result in excessive tensile stress on the bolts.

Tightening bolts

� Use bolts that are long enough to be countered with lock nuts.

Place washers under the bolt head and the nuts.

� Tighten the bolts crosswise with same torque, using a torque

wrench. Flange connections in treatment plants are often exposed

to changing loads. It is therefore important that these connections

are regularly checked and re-tightened according to the mainte-

nance schedule.

1. Introduction

� Flanges are used where tight yet detachable connections are

required in a pipe system. The dimensions must conform to DIN

EN 1092-1 PN 10.

� To ensure that the threads do not seize, we recommend applying

an anti-seize agent, e.g. molybdenum sulphide.

� When choosing the sealing material, observe the chemical and

thermal requirements.



10.1 PKS® manholes

Sewage pipe systems include a number of shafts and special

constructions for inspection, flow control, etc. We therefore offer

a range of manholes and special constructions in polyethylene

and polypropylene for profiled sewage pipes systems. Compo-

nents made from these materials ensure that all connections

throughout the entire sewage system can be welded. Differ-

ences in material properties such as response to settling must

thus only be determined once.

Normally, PKS® manholes feature a base made in polyethylene

or polypropylene and a top part consisting of concrete manhole

pipes according to DIN 4034. These vertical pipes transfer the

traffic load directly to the manhole wall. The manhole section

that is in direct contact with the wastewater and groundwater

is thus made in corrosion-resistant PE or PP. Depending on the

expected load, it is also possible to use manholes that are made

entirely of PE 100 or PP-R.

The manholes are equipped with an entry, steps or a ladder.

PKS® manholes feature a welding socket and a spigot for

connection to the PKS® pipes. We also supply manholes with

extruded flumes and sockets with smooth ends. Also available

are special constructions (e.g. with customised spigots for con-

nection to existing pipes).

PKS® manholes offer similar advantages as PKS® pipes, such as

a light-coloured inside surface for easy inspection, low weight

and smooth surfaces preventing deposits.

Advantages of PKS® manholes

� Light-coloured inside layer for easy inspection

� Low weight

� Manholes up to DN 3500

� Smooth inside and outside finish

� Designed for fast installation

� Fully pre-assembled at the factory


� Low pressure loss due to

minimised friction

Fig. 136 - PKS® inspection hole, with straight flume Fig. 137 - PKS® inspection manhole, with angled flume

Static load

Manholes that are exposed to high traffic loads can be equipped

with a load distribution plate made in reinforced concrete. The

load distribution plate transfers the traffic load to the surround-

ing ground so that the axial forces acting on the manhole are

significantly reduced.

PKS® manholes and special constructions are individually de-

signed by our technical department, taking into account the

static strength requirements. Each shaft is thus tailor-made to

meet the actual load requirements on site. A questionnaire for

the dimensioning of manholes and a manhole data sheet can

be found on pages 46, 47 and 50.


Table 13 - Standard inspection manhole

Note:

FRANK GmbH does not produce or supply concrete cones, levelling

rings and reinforced concrete covers.

DN1[mm]

DN2[mm]

h[mm]

I[mm]

h1[mm]

h2[mm]

300 1000 1000 1600 170 530

400 1000 1000 1600 170 430

500 1000 1000 1600 170 330

600 1200 1200 1800 170 430

700 1500 1300 2000 170 430

Fig. 138 - System drawing of inspection manhole

PKS® inspection manhole

Sewage pipe systems from DN 300 to DN 700 are normally

equipped with inspection manholes where the cross-section

of the sewage pipe extends across the width of the manhole

sleeve. Inspection manhole sizes:

DN 1000 for PKS® pipes from DN 300 to DN 500

DN 1200 for PKS® pipes DN 600

DN 1500 for PKS® pipes DN 700

The flume of the inspection manhole includes a raised berm that

gradually slopes to the bottom of the pipe and is available as a

straight section or as an angled component.

The upper part of the manhole consists of concrete pipe sections

that allow for levelling with the final ground level.

The height of the bottom part of the manhole made in PE 100

or PP can be adjusted to suit the pipe system layout. As a rule,

the PKS® manhole bottom section should extend above the

highest known aquifer level!

For special constructions and manholes with non-standard

dimensions, contact our technical department.


10.2 PKS® standard manhole - inspection manhole

Fig. 139 - PKS® inspection manhole, with straight flume

PKS® standard manholes are available in two versions, namely as inspection manholes and as tangential manholes.


DN1[mm]

l1[mm]

l2[mm]

h1[mm]

h2[mm]

600 2000-6000 500 900 600

700 2000-6000 550 1000 650

800 2000-6000 600 1100 700

900 2000-6000 650 1200 750

1000 2000-6000 700 1300 800

1100 2000-6000 750 1400 850

1200 2000-6000 800 1500 900

1300 2000-6000 850 1600 950

1400 2000-6000 900 1700 1000

1500 2000-6000 950 1800 1050

1600 2000-6000 1000 1900 1100

1800 2000-6000 1100 2100 1200

up to 3500 on request

h2

Fig. 140 - System drawing of tangential manhole

PKS® tangential manhole

In large-diameter PKS® pipe systems from DN 600 to DN

3500, tangential manholes are the preferred option. Tangential

manholes are mounted at an offset from the centre axis of the

pipeline. This allows for the construction of the actual manhole

with DN 1000.

The tangential manhole features a flat, underwelded and slip-

proof floor that slopes towards the main pipe. It is equipped with

an entrance, steps or safety ladder and a sealing ring at the top

on which the concrete pipe sections, etc. can be placed.


10.3 PKS® standard manhole - tangential manhole

l1

h1

DN

1

DN 1000l2

Fig. 141 - PKS® tangential manhole

The joint to the reinforced concrete plate/concrete cone should

be located above the highest known aquifer level.

The tangential manhole is connected to the pipe by means of an

electrofusion socket and a spigot end attached to the main pipe.

As PKS® tangential manholes are relatively simple structures,

they offer a cost-effective solution for large-diameter sewage

pipe systems. They offer adequate access to the pipeline without

the need of large-scale structures.Table 14 - Standard tangential manhole



10.4 PKS® storm water system

As wastewater treatment plants must be supplied with a con-

stant flow rate, mixed water systems must be equipped with

storage facilities in the pipeline system so that water can be held

back during rainy periods.

Certain systems require basin overflows. PKS® profiled sewage

pipe systems made in PE can be equipped with storm water

facilities of any desired design and capacity. It is thus possible

to install upstream and downstream retention tanks and devise

overflow geometries that suit the actual site requirements.

Constructions such as inlet, throttle and retention manholes

as required according to DWA A 117 and A 128 made in plastic

can be custom-engineered and pre-assembled at the factory.

Manholes with pre-formed sockets with a diameter of up to

3500 mm can for example by factory-assembled. Construc-

tions and pipes up to DN 2400 are then connected on site by

electrofusion welding. Components with larger diameters are

normally extrusion welded.

Advantages:

� PKS® pipes require less excavation

� Smooth inside surface

� Pipe roughness k > 0.01

� No need for dry weather channel

� Material approved by DIBt

� Fully pre-assembled

� Short installation time

� Technology suitable for complex geometries

� Low maintenance costs due to good self-cleaning prop-

erties

� Designed for high loads and installation in poor ground

� Strong welded pipe connections

� Light weight for easy handling

Fig. 142 - PKS® storm water overflow DN 3000 with strainer Fig. 143 - PKS® DN 1500 storm water system



10.4 PKS® storm water system

Inlet section

In the inlet structure, the wastewater flow is normally acceler-

ated along a steep pipe section in order to prevent deposits in

the storm water tank during dry weather periods.

Storm water tank

The storm water tank acts as a temporary storage tank for

wastewater. It consists of a PKS® pipe of the required capacity.

Regulation constructions /storm water construc-tions

The regulation construction controls the outflow from the storm

water tank to the pipeline system by means of a throttle (throttle

manhole) or with a pump (pump shaft).

Storm water constructions are equipped with an overflow res-

ervoir inside the manhole, which also acts as strainer for solids

and sediments. When the maximum retention capacity of the

system is reached, the reservoir overflows.

Fig. 144 - Storm water overflow DN 3500 with overflow reservoir

Fig. 145 - System drawing of PKS® storm water system

PKS® inlet manhole with acceleration channel

Safety steps

Reservoir

PKS® storm water tank with overflow reservoir



10.5 PKS® special constructions - examples

Fig. 146 - PKS® tangential manhole, angled, with stepped section and reduction to Y-piece

Fig. 147 - PKS® Y-piece, flange-mounted

Fig. 148 - PKS® infiltration manholes Fig. 149 - PKS® DN 2300 overbridge


Fig. 150 - PKS® DN 3000 flushing and overflow manhole Fig. 151 - PKS® Secutec DN 2000 (DN 2000 storm water system with leakage monitoring, DIBt-approved)


10.5 PKS® special constructions - examples

Fig. 152 - PKS® round-to-square adapter Fig. 153 - PKS® silo DN 3000


Fig. 154 - PKS® pipes ready for installation

Fig. 155 - Modern machinery guarantees consistent high product quality

11. Project reports

11.1 Neckar culvert: Large-diameter spiral pipes made in polyethylene

Two parallel spiral pipes are installed along a 190 metre stretch

under the Neckar river. Laid at a depth of up to eleven metres,

the new system is designed for long-term tightness.

Over the last few years, sewage system operators have become

increasingly aware of the environmental issues associated with

sewage and wastewater. Local governments are addressing

the problem of leaks in drains, manholes and pipeline systems.

polyethylene (PE 100), as it offers a number of distinct advan-

tages over conventional materials. As the properties of modern

polyethylene materials can be fine-tuned, pipe systems made

from this material can be equally optimised for any specific task.

Key parameters are the internal pressure strength across the

pipe's service life, resistance against slow and fast crack propa-

gation and the pipe's mechanical strength.

Large-diameter spiral pipes made in polyethylene

Focussing on the improvement of the internal pressure strength,

the resistance to slow and fast crack propagation and the

long-term mechanical strength, FRANK has developed the

profiled sewage pipe (PKS®) and associated fittings made in

polyethylene.

Over many years, FRANK has been able to devise a production

process for lightweight yet dimensionally stable products that

are resistant to chemicals and mechanical forces and have an

exceptionally long service life.

As a result, operators demand pipes made from materials that are less prone to leakage.

Recent studies show that leaks occur not only in old pipes but

also in recently installed sewer lines. One of the reasons for this

are flaws in the system design, such as the use of unsuitable

pipe and socket material, resulting in leaking socket connec-

tions. Pipelines made in rigid materials are particularly prone to

leaking, as they can burst suddenly under a short-time load. The

resulting cracks and fractures do not only lead to the escape of

sewage into the environment but reduce the static load strength

of the pipeline. In such cases, organic and inorganic substances

contained in the sewage can pollute the groundwater, while

fresh water might infiltrate the sewage system. As the number of

combined sewer systems that collect rainwater runoff, domestic

sewage, and industrial wastewater decreases, sewers carrying

highly loaded wastewater need to be tighter than ever, as any

leaks here can cause even more serious pollution. Operators

are thus on the lookout for pipe materials and connecting tech-

niques that guarantee lasting tightness of the pipeline system.

Based on its many years of practical experience with pipeline

systems made in polyethylene (PE 80 /PE 100), FRANK GmbH

has developed a range of fittings and system components that

meet the ever more stringent requirements for the various ap-

plications, including sewage discharge. The solutions developed

by FRANK also meet the latest plant engineering standards. One

product that clearly stands out here is the spiral pipe made in

A distinct feature of modern pipes from FRANK GmbH is the

integrated electrofusion socket. The co-extruded yellow inside

layer made in PE allows for efficient revision procedures and

inspections by camera.

The projects described here demonstrate the above advantages

of FRANK pipes and fittings and their practical usage. Large-

diameter spiral profiled sewage pipe systems from FRANK are

currently being installed on many industrial sites, in sewage

treatment systems, on landfill sites and in road construction.

They are also particularly suitable for pipe relining.


11. Project reports

11.1 Neckar sewage pipeline under-river crossing: Large-diameter spiralpipes made in polyethylene

Sewer lines crossing the Neckar at Mannheim

The "Grabenstrasse" culvert was first laid in 1903 as a riveted iron

pipe with an inside diameter of 1400 mm. It was connected to

a combined sewage and rain water pipe system that extended

under the city centre of Mannheim. In October 2002, the pipe

was to be cleaned, which required the culvert to be pumped

empty. Over the nearly 100 years since its installation, the load on

the pipe increased as the river bed was lowered several times

to provide a deeper shipping channel. When being emptied,

the culvert became buoyant in the river and eventually broke.

Its repair became an urgent matter.

The engineering firm of de la Motte & Partner Ingenieurgesells-

chaft mbH based in Reinbeck near Hamburg was commis-

sioned to perform a feasibility study. It subsequently drew up the

construction plans and supervised the construction based on a

cost guarantee. The actual construction work was performed

by the Neckardüker Consortium set up by Diringer & Scheidel,

Mannheim, which was responsible for the pipeline and manhole

construction, and Bohlen & Doyen, Wiesmoor, which carried

out the hydraulic engineering work. Together with the sewage

system operator and the water management department of

the city of Mannheim, the partners developed a solution that

met the actual site requirements. One main concern was the

fluctuating water levels in the pipe (depending on the weather).

The pipe section also had to allow for a high flow rate to prevent

deposits. In addition, the culvert had to last for a long period

of time and had to be installed in such a way that it would not

become buoyant under any circumstances.

One key advantage of the chosen PE pipe over other materials

is its light weight, which allows for easy handling. In addition,

the smooth pipe inside prevents deposits. The chosen material

also had to withstand exceptionally high loads when the pipe

is empty, as it is exposed to a high water pressure. In addition,

the pipe had to be anchored in the river bed to prevent floating.

Fig. 156 - Available in lengths of up to 12 m

Requirements, objectives and certification

During the planning phase, the system operator requested

detailed static load calculations according to ATV-DVWK-A 127

as amended, based on specific water levels and trench base

heights. These revealed that the FRANK pipes meet the require-

ments as regards ring stiffness when the pipes are fully filled as

well as when they are completely empty, for example during a

repair or inspection. In addition, the spiral PE 100 pipes met the

following key requirements:

� Long-term tightness of welded connections between the

various components

� Constant production conditions

� Seamless quality control

� Easy installation on site

� Excellent cost-efficiency

� Certified long-term durability

The river was crossed by two PKS® pipes from FRANK GmbH

with DN 800 and DN 1400 that were installed parallel to each

other. They were welded together on the river bank and then

laid in a boxed steel structure where all fittings were mounted

until the complete pipe system was lowered to the bottom of

the Neckar river on the 12 August 2003.

To allow for easy access for maintenance or cleaning, the two

pipe strings were equipped with a revision manhole each located

in the foreland area.

After the boxed steel structure was filled with waterproof con-

crete to prevent it from floating, the under-river pipe section

was connected to the existing pipeline system. The completed

project was inspected and accepted by the client on the 6

November 2003.

Fig. 157 - Neckar sewage pipeline prior to installation in river bed


11. Project reports

11.1 Neckar culvert: Large-diameter spiral pipes made in polyethylene

Fig. 158 - Neckar under-river pipeline section is being lowered to the bottom of the river bed

PE - the ideal material for this project

The companies involved in this project were already familiar with

the advantages of plastic pipes in sewer systems. The decision

to use PE 100 pipes in this projects was based on both technical

and commercial considerations.

PE 100 - a cost-effective solution

Spiral pipes, pressure pipes and fittings made in PE 100 have

a relatively low specific weight of 0.959 g/cm3, which is of sig-

nificant advantage for the handling and installation of the com-

ponents. This helps of course lower the installation costs. Spiral

pipes with a diameter of more than DN 300 can be manufactured

in a flexible, low-cost production process. During the planning

phase, the relevant positive experiences from other projects

were highlighted to convince the client as well as the construc-

tion consortium of the advantages of the proposed solution.

Technical advantages of PE 100

Compared with conventional pipe materials (manufactured ac-

cording to the Darmstadt method), PE 100 offers better chemical

resistance, higher operational safety and significantly improved

abrasion resistance. In addition, they are also easier to weld and

guarantee more durable tightness of the system. From an envi-

ronmental point of view, PE 100 can be produced with relatively

little energy and the material is fully recyclable.

Certified long-term durability

Pipe systems made in PE 100 have been used for many decades

for the transport of gas, water, wastewater and substances that

are water pollutant and have thus an excellent track record. The

tested service life of such installations is currently at around 50

years, whereby experts expect this figure to increase to 80

to 100 years as tests continue. ISO 9080 (previously ISO/TR

9080) describes a scientifically verified extrapolation method

that allows for predictions regarding the long-term durability of

thermoplastic materials. This method is based on the Arrhenius

law. Based on long-term data of pressurised pipe specimens

exposed to high temperatures, it is possible to determine the

service life of pipes at lower temperatures. The relevant extrapo-

lation factors are laid down in ISO 9080. The minimum service

life curve in DIN 8075 for PE 100 has been devised on the basis

of the same principle. By opting for Hostalen CRP 100 Black

(PE 100), manufacturers and users of pipe systems can now

choose a material with a calculated service life of more than

100 years. This multimodal, third-generation PE compound is

produced by Basell Polyfone GmbH at its plant in Frankfurt/Main

in a multi-stage polymerisation plant. Hostalen CRP 100 Black

(PE 100) has been approved by the German Institute for Civil

Engineering (DIBt) in Berlin.

Weldable materials for permanently tight pipe sys-tems

The guide values for welding parameters for this multi-modal

material as regards pre-heating, joining pressure build-up and

cooling time under joining pressure, etc. are laid down in the lat-

est edition of DVS 2207 for pipes and plates made in PE (PE 100).

Summary

Wound large-diameter pipes from FRANK GmbH made in

multi-modal PE (PE 100) materials allow for the fast and cost-

efficient production of heavy-duty pipe systems, manholes

and constructions with guaranteed long-term tightness. As the

pipes are equipped with integrated electrofusion sockets, they

are easy to connect by means of welding. The light-coloured,

smooth and abrasion-resistant inside surface of the pipe allows

for easy inspection as well as trouble-free operation.


11. Project reports

11.2 Steinhäule wastewater treatment plant

Plant requirements

The new construction of the denitrification and distribution basins

includes eight cascades with inlet and outlet pipelines. Each

cascade level has a capacity of 2400 m³.

The overground and underground pipe systems had to meet

the following requirements:

� Pressure pipes with an inside diameter of DN 1000 to DN

1400 for flexible water transport and distribution.

� The underground pipelines include various special com-

ponents such as T-pieces, valves, wall connections and

reducers.

� Flow capacity: 55 to 70 m3/min

� Operating temperatures: 5 and 20 °C respectively

� Max. permissible operating / system pressure: 1.5 bar

� Plant service life: > 50 years

Introduction

New statutory regulations for the treatment of wastewater

and sewage have forced plant operators to improve the ef-

fectiveness of their treatment systems. Further improvements

of the quality of the discharged water are likely to focus on the

retention of ecologically critical substances that are virtually

non-biodegradable, such as residues from drugs and nitrates

from agricultural land use.

Future regulations will be based on the standards set by the

European Union, which is in the process of devising communal

directives for the protection of waterways and groundwater,

and the licensing of treatment plants.

In order to tackle these challenges, the cooperative behind the

Steinhäule sewage treatment plant realised that it needed to

increase the capacity of its plant and invest in modern technol-

ogy. The plant is to be extended by additional clarifying basins

and a filtration unit so that its can be upgraded in line with the

latest statutory requirements.

The installation of overground pressure pipes with an inside

diameter of DN 1000 to DN 1400 for the underground denitri-

fication and distribution basins with many custom-engineered

components required a detailed technical planning procedure,

including extensive static strength calculations for the envisaged

pipe dimensions and site layout.

For this project, spiral large-diameter pipes made in PE 100 were

chosen, which were then installed in cooperation with an installa-

tion company and under the supervision of an engineering firm.

Catchment area of Steinhäule plant

The Steinhäule treatment plant is located near the river Danube,

downstream of the power plant of "Böfinger Halde". It is owned

by a consortium that includes the city councils of Ulm, Neu-Ulm,

Senden and Blaubeuren as well as the towns of Berghülen,

Blaustein, Dornstadt, Illerkirchberg, Illerrieden, Schnürpflingen

and Staig. The wastewater from the above areas is treated ac-

cording to the statutory regulations and then discharged into

the Danube.

The plant extends over an area of 11 hectares. Every day, the

effluent of around 200,000 people in the catchment area is

treated in the Steinhäule plant. This corresponds to a wastewater

volume of about 80,000 to 100,000 m³ a day. Around 40 % of the

wastewater is produced by industry and other businesses. In the

treatment process, approx. 20 to 40 tons of sludge (dry matter)

is removed, which is incinerated. It takes about ten hours for the

water to pass through the treatment plant. In comparison, given

the self-purifying power of the Danube, it would take about ten

days to treat the same amount of wastewater, if it were directly

discharged into the river.

Fig. 159 - Steinhäule wastewater treatment plant


Static strength calculations

The static strength calculations for this project were extremely

demanding. The standard method according to DVS 2210-1

was used to determine the dimensions of the pipes without

fittings, as this method allows for the accurate calculation of

the internal pressure stress, the support spans and the forces

acting on fixed points due to longitudinal expansion. The results

were then used for the construction of the straight pipe sec-

tions between the various fittings. The figures showed that the

PE 100 pipeline could be installed with the same support span

as a stainless steel system.

11. Project reports


Engineering aspects

Due to the specific requirements to be met by the upgraded

plant and the overground installation of the pipes, it was neces-

sary to carry out detailed static strength calculations, which was

done during the extended technical planning phase.

The calculations focused on the effects of increased inside pres-

sure and thermal expansion, taking into account the design of

the fixed points and the required support spans.

The relevant static strength values for PE 100 were made avail-

able by the material producer.

Pipe and fitting production

FRANK GmbH based in Mörfelden has more than 45 years of

experience in the production of PE pipe materials and is one

of the leading manufacturers of spiral pipes in Europe. FRANK

GmbH also operates plants in Poland and New Zealand.

The pressure pipes, bends and T-pieces for this project were

manufactured by two subsidiaries of FRANK GmbH in Wölfer-

sheim. Thanks to its flexible, state-of-the art production machin-

ery, the Wölfersheim plant is well equipped for the production

of customised pipe dimensions of up to DN 3500 in PE and PP.

In order to minimise the on-site installation costs, most pipeline

segments (pipe with fittings) were pre-assembled at the fac-

tory in Wölfersheim. These segments with lengths between 4

and 8 metres were then transported on a low-loader to the

construction sites.

The static strength calculations of the pressure pipes, bends and

fixed flange fittings were performed by FRANK Deponietechnik

GmbH in cooperation with the engineering firm Ingenieurbüro

Pöltl. These calculations were then verified by LGA in Nuremberg

and Dr. Ing. Dietmar H. Maier, Karlsruhe. The bearing points

were subsequently calculated by Ingenieurbüro Brandolini &

Seitz in Ulm.

Fig. 160 - Finite element model of DN 1400 T-piece (source: LGA Nuremberg)

Fig. 161 - Finite element model of DN 1400 T-piece (source: LGA Nuremberg)

Finite element analysis of fittings

The fittings such as T-pieces, bends, reducers and fixed flanges

needed to be evaluated separately. These fittings were all made

from solid spiral pipe material to ensure that they had the cor-

rect wall thickness. The relevant calculations were performed

using the finite element method (FEM). The main advantage of

this method lies in the fact that it can be used for calculations in

a wide range of disciplines, as each component is divided into a

large number of very small elements. Subsequently, the forces

acting on these elements are evaluated in order to determine

the forces that affect the actual component. With this approach,

it is thus possible to determine the wall thickness required for

any possible geometric shape.


11. Project reports


Result

Considering the requirements, calculations and analyses, the

consortium decided on the 23 July 2006 to use pipes and fittings

made in PE 100 for the connection between the denitrification

basins. The entire installation was completed within only two

months. The total weight of the installed pipes and fittings was

around 100 tons.

The experiences from the Steinhäule project will be evaluated

for future projects as they show that PE 100 is a viable alternative

to stainless steel pipelines in plant construction.

Fig. 162 - Inside the treatment plant

Fig. 163 - Supports/clamps for r PKS® pipes

Fig. 164 - PKS® T-piece with elbow

Fig. 165 - PKS® pipe flange connections


11. Project reports

11.3 Sureline® pipes for Hamburg pressure drainage system

Introduction

The Hamburg city drainage authority HSE needed to construct a

pressure pipeline to connect three pump stations in the districts

of Bergedorf to the wastewater mains. The locality features a

major thoroughfare (Kurt-A.-Körber-Chaussee) with a number

of industrial estates on both sides. There is thus a lot of traffic at

all times of the day. In addition, the pipeline is crossed by numer-

ous house connections. Considering these conditions and the

good results from previous projects where pipes were laid under

a riverbed by means of horizontal hydraulic drilling, HSE decided

to use this advanced installation technology also for this project.

Construction

HSE completed the planning of this highly complex project within

around four to five months. The actual construction phase took

only three months.

The pipes were welded on site (butt welding with heating ele-

ment) and subsequently pulled into the drilled channel. One

section of the system (section A, length 1145 m) required the

use of a stainless steel sleeve (508 x 9.5) as the pulling forces

during installation (friction, pipe weight) were deemed too high

for plastic pipes. The remaining section B was drilled in three

parts (220 m, 270 m and 420 m) for installation without a pro-

tective sleeve. The connection of the individual Sureline® pipes

was extremely easy, as they could be welded according to

the DVS 2207 parameters without any further preparation or

reworking. The actual pulling forces during installation measured

on the pipe were between 120 and 200 kN, which is about half

of the permissible limit forces. The construction progress was

constantly monitored by HSE and the contractors worked closely

together. This complex project could be brought to a successful

conclusion with a final pressure test.

Another aspect that spoke for this method was the excellent

properties of the proposed pipe material. Apart from the well-

known advantages of PE 100 pipes over conventional pipe

material, the Sureline® pipes from FRANK offered unrivalled

resistance against slow crack propagation, which makes them

the ideal solution for alternative installation technologies. Other

requirements laid down by HSE such as long-term E modulus,

resistance to fast crack propagation, and compliance with the

ZP 14.6.36 standard were easily met by the PE 100 pipes, which

have been tried and tested in similar projects.

Apart from the high quality of the pipe material, HSE was also

keen to find a pipeline installation contractor that had the neces-

sary expertise and experience. The successful bidder needed

to meet the requirements laid down in DVGW GW 301 or GW

302 (group GN 2) respectively.

After careful examination of all submitted documents, HSE chose

Vorwerk GmbH based in Tostedt and its partner company Nacap

B.V. from Eelde (Netherlands) as the pipe installation contractors.

Planning

The total pipeline length

for this project was

around 2000 m to be

completed with pipes

of various diameters

(da 280 - da 400, SDR

11). HSE decided to use

sewage pipes with a

l ight-coloured inside

layer from the FRANK

Sureline® range. Fig. 166 - Sureline® pipe 315 x 18.6 mm

Summary

Despite the difficult site conditions, HSE was able to complete

this project in a most cost-effective manner without compromis-

ing the quality of the construction. Compared with the estimated

open-trench installation costs of around EUR 3m, the project was

actually completed at a total cost of approximately EUR 1.8m,

which corresponds to cost savings of around 60%.

This was mainly due to the fact that the Sureline® pipes were

installed at a depth of around 6 to 9 m (in section A) and around

3.0 m (in section B). As most underground supply and discharge

pipes and other infrastructure lines (gas, telephone, power)

are installed at a much higher level, work at this depth could

progress unhampered. The only slightly costly item that was

required with this solution was a shaft with a depth of 10 metres.

Overall, the chosen installation was the most economical one.

What is more, this project showed that pipe systems that are

readily available in the market and modern installation methods

can be effectively combined to lay pipelines in urban areas with

minimum disruption to other supplies.


11. Project reports

11.4 Storm water channel Sportlaan, Netherlands

Project descriptionMunicipality of Dedemsvaart, Province of Overijssel, Netherlands

The storm water tank made from PKS® pipes was to replace

an old concrete storm water system. By renewing the storm

water tank, the leaking concrete construction was to be put out

of operation, while the capacity of the tank was to be increased

to 450 m3.

The municipal council and its contractor Sallandse Wegebouw

opted for a storm water tank made in PE 100, as these plastic

pipes can be tightly sealed by means of electrofusion sockets

and have a perfectly smooth inside surface so that no additional

flushing system for cleaning would be required.

In addition, PKS® pipes can be installed quicker than other pipes,

doing away with the need for costly, large water retention tanks.

Fig. 167 - Installation of PKS® pipes

Fig. 168 - Two DN 1800 pipe strings of 78 m in length, installed between the road and a pond

The delivery included 156 m PKS® DN 1800 pipes, a number of

PKS® DN 1800 30° bends, a PKS® DN 1800 inlet section and a

PKS® DN 3000 overflow/pump shaft.

All pipes, bends and manholes were welded and installed within

two weeks by Sallandse Wegebouw.

Fig. 169 - Laying of PKS® pipe DN 1800, in pre-welded sections of 18 m

Fig. 170 - Installation of DN 3000 overflow/pump shaft


12. Standards and regulations

FRANK pipes and fittings are made from standardised moulding materials and produced according to recognised German and

international standards. The list below is an excerpt of the standards, technical codes and regulations referred to in our catalogue:

DIN/DIN EN/DIN EN ISO

DIN 1910-3Welding - Welding of plastics - Processes

DIN 1989Rainwater harvesting systems

DIN 4102-1Fire behaviour of building materials and building compo-nents - Part 1: Building materi-als; concepts, requirements and tests

DIN 4262-1Pipes and fittings for subsoil drainage of trafficked areas and underground engineer-ing - Part 1: Pipes, fittings and their joints made from PVC-U, PP and PE

DIN 4266-1Drainage pipes for landfills - Part 1: Drainage pipes made from PE and PP

DIN 8074Polyethylene (PE) - Pipes PE 80, PE 100 - Dimensions

DIN 8075Polyethylene (PE) pipes - PE 80, PE 100 - General quality requirements, testing

DIN 8077Polypropylene (PP) pipes - PP-H, PP-B, PP-R, PP-RCT - Dimensions

DIN 8078Polypropylene (PP) pipes - PP-H, PP-B, PP-R, PP-RCT - General quality requirements and testing

DIN 16928Pipes of thermoplastic materi-als; pipe joints, Elements for pipes, laying; general direc-tions

DIN 16961-1Thermoplastics pipes and fittings with profiled wall and smooth pipe inside - Part 1: Dimensions

DIN 16961-2Thermoplastics pipes and fittings with profiled wall and smooth pipe inside - Part 2: Technical delivery specifica-tions

DIN 16962-4Pipe joint assemblies and fittings for types 1 and 2 poly-propylene (PP) pressure pipes; adaptors for fusion jointing, flanges and sealing elements; dimensions

DIN 16962-5Pipe fittings and joint as-semblies for polypropylene (PP) pressure pipes - Part 5: General quality requirements and testing

DIN 16962-6Pipe joints and elements for polypropylene (PP) pres-sure pipelines types 1 and 2; injection moulded elbows for socket-welding; dimensions

DIN 16962-7Pipe joints and elements for polypropylene (PP) pressure pipelines types 1 and 2; injec-tion moulded tee pieces for socket-welding; dimensions

DIN 16962-8Pipe joints and elements for polypropylene (PP) pres-sure pipelines types 1 and 2; injection moulded sockets and caps for socket-welding; dimensions

DIN 16962-9Pipe joint assemblies and fittings for types 1 and 2 poly-propylene (PP) pressure pipes; injection moulded reducers and nipples for socket welding; dimensions

DIN 16962-10Pipe joint assemblies and fit-tings for types 1 to 3 polypro-pylene (PP) pressure pipes; injection-moulded fittings for butt welding; dimensions

DIN 16962-12Pipe fittings and joint as-semblies for polypropylene

(PP) pressure pipes - Part 12: Flange adapters, flanges, seal-ing rings for socket welding; dimensions

DIN 16963-4Pipe joint assemblies and fit-tings for high-density polyeth-ylene (PE-HD) pressure pipes; adaptors for fusion jointing flanges and sealing elements; dimensions

DIN 16963-5Pipe fittings and joints and assemblies for PE 80 and PE 100 polyethylene pressure pipes - Part 5: General quality requirements and testing

DIN 16963-6Pipe joint assemblies and fit-tings for high-density polyeth-ylene (PE-HD) pressure pipes; injection-moulded fittings for butt welding; dimensions

DIN 16963-7Pipe joint assemblies and fit-tings for high-density polyeth-ylene (PE-HD) pressure pipes; fittings for resistance welding; dimensions

DIN 16963-8Pipe joints and elements for high density polyethylene (HDPE) pressure pipelines types 1 and 2; injection mould-ed elbows for socket-welding; dimensions

DIN 16963-9Pipe joints and elements for high density polyeth-y lene (HDPE) pressure pipelines types 1 and 2; injection moulded tee pieces for socket-welding; dimen-sions

DIN 16963-10Pipe joints and elements for high density polyeth-y lene (HDPE) pressure pipelines types 1 and 2; injection moulded sockets and caps for socket-welding; dimensions DIN 16963-11Pipe fittings and joint assem-

blies for pressure pipes made from types PE 80 and PE 100 polyethylene - Part 11: Dimen-sions of bushings, flanges and sealing elements, for socket welding

DIN 16963-14Pipe joint assemblies and fittings for types 1 and 2 high-density polyethylene (HDPE) pressure pipes; injection moulded reducers and nipples for socket welding; dimensions

DIN EN 476General requirements for components used in drains and sewers

DIN EN 752Drain and sewer systems outside buildings

DIN EN 805Water supply - Requirements for systems and components outside buildings

DIN EN 1091Vacuum sewerage systems outside buildings

DIN EN 1295-1Structural design of buried pipelines under various condi-tions of loading - Part 1: General requirements

DIN EN 1555Plastics piping systems for the supply of gaseous fuels - polyethylene (PE)

DIN EN 1610Construction and testing of drains and sewers

DIN EN 1671Pressure sewerage systems outside buildings

DIN EN 1778Characteristic values for welded thermoplastic con-structions - Determination of allowable stresses and mod-uli for design of thermoplastic equipment


ISO

ISO 3Preferred numbers - Series of preferred numbers

ISO 161-1Thermoplastics pipes for the conveyance of fluids - Nominal outside diameters and nominal pressures - Part 1: Metric series

ISO 4065Thermoplastics pipes - Univer-sal wall thickness table

ISO 4427Plastics piping systems. Poly-ethylene (PE) pipes and fittings for water supply

ISO 11922-1Thermoplastics pipes for the conveyance of fluids - Dimen-sions and tolerances

ISO 12176Plastics pipes and fittings - Equipment for fusion jointing polyethylene systems

ISO/TS 19911Plastics pipes and fittings - Format of a technical file for characterizing PE spigot end fittings

PAS

PAS 1065Spirally wounded pipes made from polyethylene (PE 100) - tangentially extruded - Dimen-sions, technical requirements and test

PAS 1075Pipes made from polyethylene for alternative installation tech-niques - Dimensions, technical requirements and testing


DIN EN 10204Metallic products - Types of inspection documents

DIN EN 12201Plastics piping systems for water supply, and for drainage and sewerage under pres-sure - Polyethylene (PE)

DIN EN 12255-10Wastewater treatment plants - Part 10: Safety principles

DIN EN 12943Filler materials for thermo-plastics - Scope, designation, requirements, tests

DIN CEN/TS 13244-7Plastics piping systems for buried and above-ground pressure systems for water for general purposes, drainage and sewerage - Polyethylene (PE) - Part 7: Guidance for the assessment of conformity

DIN EN 13476-3Plastics piping systems for non-pressure underground drainage and sewerage - Structured-wall piping sys-tems of unplasticized poly(vinyl chloride) (PVC-U), polypro-pylene (PP) and polyethylene (PE) - Part 3: Specifications for pipes and fittings with smooth internal and profiled external surface and the system, type B

DIN CEN/TS 13476-4Plastics piping systems for non-pressure underground drainage and sewerage - Structured-wall piping sys-tems of unplasticised poly(vinyl chloride) (PVC-U), polypro-pylene (PP) and polyethylene (PE) - Part 4: Guidance for the assessment of conformity

DIN EN 13598-2Plastics piping systems for non-pressure underground drainage and sewerage - Un-plasticized poly(vinyl chloride) (PVC-U), polypropylene (PP) and polyethylene (PE) - Part 2: Specifications for manholes and inspection chambers in traffic areas and deep under-ground installations

DIN EN 14830Thermoplastics inspection chamber and manhole bases - Test methods for buckling resistance

DIN EN ISO 178Plastics - Determination of flexural properties

DIN EN ISO 228-1Pipe threads where pressure-tight joints are not made on the threads - Part 1: Dimensions, tolerances and designation

DIN EN ISO 472Plastics - Vocabulary

DIN EN ISO 527-1Plastics - Determination of ten-sile properties - Part 1: General principles

DIN EN ISO 527-2Plastics - Determination of tensile properties - Part 2: Test conditions for moulding and extrusion plastics

DIN EN ISO 1043-1Plastics - Symbols and ab-breviated terms - Part 1: Basic polymers and their special characteristics

DIN EN ISO 1872-1Plastics - Polyethylene (PE) moulding and extrusion ma-terials - Part 1: Designation system and basis for speci-fications

DIN EN ISO 1872-2Plastics - Polyethylene (PE) moulding and extrusion mate-rials - Part 2: Preparation of test specimens and determination of properties

DIN EN ISO 9080Plastics piping and ducting systems - Determination of the long-term hydrostatic strength of thermoplastics materials in pipe form by extrapolation

DIN EN ISO 9967Thermoplastics pipes - Deter-mination of creep ratio

DIN EN ISO 9969Thermoplastics pipes - Deter-

mination of ring stiffness

DIN EN ISO 12162Thermoplastics materials for pipes and fittings for pressure applications - Classification, designation and design coef-ficient

DIN EN ISO 1873-1Plastics - Polypropylene (PP) moulding and extrusion ma-terials - Part 1: Designation system and basis for speci-fications

DIN EN ISO 9001Quality management sys-tems - Requirements

DIN EN ISO 9969Thermoplastics pipes - Deter-mination of ring stiffness



AD advice sheets

AD 2000-Advice Sheet HP 120 RConstruction regulations - Thermoplastic piping - Manu-facture and testing of pressure vessels AD 2000-Advice Sheet HP 512 RConstruction regulations - De-sign examination, final testing and pressure testing of piping

DVGW

DVGW GW 320-1Rehabilitation of gas and wa-ter pipelines by slip lining with annulus

DVGW GW 320-2Rehabilitation of gas and wa-ter pipelines by close fit lining with PE pipes - requirements, quality assurance and testing

DVGW GW 335-A1Plastic pipeline systems in gas and water supply - require-ments and testing - part A1: PVC-U pipes and fittings made from pipes for water supply

DVGW GW 335-A2Plastic pipeline systems in gas and water supply - require-ments and testing - part A2: PE 80 and PE 100 DVGW GW 335-B2Plastic pipeline systems in gas and water supply - require-ments and testing - part B2: PE 80 and PE 100 fittings

DVGW W 400-2Engineering rules for water supply systems - part 2: con-struction and testing

DVS

DVS 2201-1Testing of semi-finished prod-ucts made of thermoplastics - Basics - indications

DVS 2202-1Imperfections in thermoplastic welding joints - Features, de-scriptions, evaluation

DVS 2205-1Design calculations for con-tainers and apparatus made from thermoplastics - Char-acteristic values

DVS 2207-1Welding of thermoplastics - Heated tool welding of pipes, pipeline components and sheets made of PE-HD

DVS 2207-3 Supplement 1Welding of thermoplastics - Hot-gas string-bead welding and hot-gas welding with torch separate from filler rod of pipes, pipe components and sheets - Welding parameters

DVS 2207-4Welding of thermoplastics - Extrusion welding of pipes, piping parts and panels - Pro-cesses and requirements

DVS 2207-11Welding of thermoplas-tics - Heated tool welding of pipes, piping parts and panels made of PP

DVS 2207-15Welding of thermoplas-tics - Heated tool welding of pipes, piping parts and panels made of PVDF

DVS 2208-1Welding of thermoplastics - Machines and devices for the heated tool welding of pipes, piping parts and panels

DVS 2210-2Industrial piping made of thermoplastics – Designing, structure and installation of two-pipe systems

DVS 2211Welding of thermoplastics - Welding fillers - Marking, re-quirements and tests

DWA (ATV-DVWK)

DWA-A 100Guidelines of Integrated Urban Drainage (IUD)

ATV-A 106Design and Construction Plan-ning of Wastewater Treatment Facilities

DWA-A 110Hydraulic Dimensioning and Performance Verification of Sewers and Drains

DWA-A 111Standards for the Hydraulic Dimensioning and the Perfor-mance Verification of Storm-water Overflow Installations in Sewers and Drains

DWA-A 112Hydraulic Dimensioning and Performance of Special Struc-tures in Drain and Sewer Systems

DWA-A 116-1Special Sewerage Systems - Part 1: Vacuum Sewerage Systems Outside Buildings

DWA-A 116-2Special Sewerage Systems - Part 2: Pressure Sewerage Systems Outside Buildings

DWA-A 117Dimensioning of Stormwater Holding Facilities

DWA-A 118Hydraulic Dimensioning and Verification of Drain and Sewer Systems

DWA-A 125Pipe Jacking and Related-Techniques

ATV-DVWK-A 127Static Calculation for the Reha-bilitation of Drains and Sewers

ATV-A 128Standards for the Dimension-ing and Design of Stormwa-ter Structures in Combined Sewers

DWA-A 138Planning, Construction and Operation of Facilities for the Percolation of Precipitation Water

DWA-A 139Construction and Testing of Drains and Sewers

ATV-DVWK-A 142Sewers and Drains in Water Catchment Areas

DWA-A 147Operating Expenditure for the Sewer System - Operating Tasks and Intervals

ATV-DVWK-A 157Sewer System Structures

DWA-A 166Plants for Centralised Storm-water - Treatment and Re-tention

ATV-DVWK-A 198Standardisation and Deriva-tion of Dimensioning Values for Wastewater Facilities

DWA-A 222Principles for Dimensioning, Construction and Operation of Small Sewage Treatment Plants with Aerobic Biologi-cal Purification Stage to 1000 inhabitant values

DWA-A 262 Principles for the Dimen-sioning, Construction and Operation of Plant Beds for Communal Wastewater

DWA-A 712General Guide for the Plan-ning of Wastewater Treatment Facilities for Industrial Plants

ATV-DVWK-A 780-2Technical Rule for Water-Pollutant Substances

DWA-M 114Energy from sewage

DWA-M 127-1Pipe Static Calculations (Land-fill Leakate Lines)



ATV-M 127-2Static Calculation for the Reha-bilitation of Drains and Sewers Using Lining and Assembly Procedures

ATV-DVWK-M 143-1Rehabilitation of Drain and Sewer Systems Outside Build-ings - Part 1: Basis

ATV-DVWK-M 176Information and Examples for Detail Planning and Technical Equipment of Facilities for Central Stormwater Treatment and Retention

ATV-DVWK-M 177Dimensioning and Design of Stormwater Overflow Systems in Mixed Water Sewers - Expla-nations and Examples

DWA-M 178Recommendations for Plan-ning, Construction and Opera-tion of Retention Soil Filters for Enhanced Stormwater Treat-ment in Mixed and Separated Systems

DWA-M 275Pipeline for the Area or Techni-cal Installation of Wastewater Treatment Plants


13. Index

AAbrasion resistance 28, 33, 34

Advantages of PKS® pipes 6

Advantages of PROFIX pipes 7

Advantages of Secutec sewage pipe

system 9

Advantages of Sureline® pipes 8

ATV-DVWK 89

BBacking ring 71

Bedding angle 38

Bending radii for Sureline® pipes 57

Buckling pressure 37, 40

Buckling stress 37, 40

Burst lining 56

Butt welding

- extruded sewage pipe 60, 67, 68

CCohesive mixed soils 39

Cohesive soils 39

Component traceability code 17

Concentric reducer 78

Connecting techniques 60, 61, 62, 63

Constant load 20

Constant speed 20

Contraction procedure 59

Cooling time for PKS® 61

Cost analysis for sewage pipe system

13

Cost saving potential for sewage pipe

systems 14

Covering conditions 39, 48

Creep rupture curve 41

Creep rupture curves - PE 100 31

Creep rupture curves - PP 32

DDarmstadt method 33

Density 30

Detachable connection 71

DIBt registration number 24

DIN 87

Divided electrofusion wire 62

Drilling rocket 56

DVGW 89

DVS Technical Code 89

DWA A 127 38

EElectrofusion socket 17

Electrofusion welding

- extruded sewage pipe 60, 65, 66

- profiled sewage pipes 60, 61, 62, 63

Elongation 42

Embedding conditions 39, 49

E modulus 30

Estimated costs of damage in sewage

pipe system 13

Explanations re. questionnaire 48

External quality assessment 24

External testing

- FNCT 22

- notch test 21

- point load test according to Hessel

21

- tensile testing of weld 23

Extruded sewage pipe 17

Extrusion method 10

Extrusion welding 60, 64

Extrusion wire 64

FFire class 30

Fixed points 43

Flange connection 70, 71

Forces acting on flexible sewage pipe

12

FRANK manhole connection socket 54

FRANK wall connection

- type PKS® 1 55

- type PKS® 2 54

- type PKS® 2a 54

Full notch creep test 21, 22

GGeneral installation guidelines

- handling 51

- storage 52

- transport 51

General welding guidelines 60

Groundwater above pipe level 37

HHandling 51

Hessel - quality assessment contract

24

High pressure cleaning 35

Homogeneous welding zone 6

Horizontal hydraulic drilling 56

House connection 69

House connection saddle 69

Hydraulic drilling 56

Hydraulic properties 28

IIdentification

- DIN 8074/8075 pressure pipes 17

- DIN 16961 spiral pipes 16

Incoming inspection 18

Inlet structure 76

In-process control 18

Inspection manhole 72, 73

Installation 38

Installation guideline 51, 52

Installation in bank 38

Installation of PKS®/Profix pipes 53

Insulation 37

Internal pressure creep test 20

Internal quality assurance

- density measurement 19

- internal pressure creep testing 20

- MFR - melt flow rate 19

- moisture content measurement 19

- ring stiffness testing 20

- tensile testing of profile 20

- tensile testing, tensile stress at yield

19

- ultrasonic testing 20

ISO 88

LLeakage test 19, 55

- gravity pipelines

- leakage testing with air 58

- pressure pipes

- contraction procedure 59

Lifting force 37

Load assumptions for standard vehicles

38, 49

Long pipe relining 56

Long-term ring stiffness 11

MManhole cover 47

Manhole data sheet 50

Manhole floor 47

Manholes

- PKS® inlet manhole 76

- PKS® inspection manhole 72, 73

- PKS® storm water overflow 75, 76

- PKS® tangential manhole 74

Material properties 30

Maximum distance between support

points 37

Maximum operating pressure 40


13. Index

Melt flow index 30

Method “L” 58

Method “W” 58

MFR - melt flow rate 19

Minimum wall thickness 40

Moisture content 19

Moulding material

- polyethylene 27, 28

- polypropylene 29

NNon-cohesive soils 39

Notch test 21

OOperating pressure 40

Operational roughness kb 36

Overbridge 77

Overpressure 40

PPAS 87

PE 100 27

PE 100 RC 8, 22

PE-el 28

Permissible buckling pressure 37

Permissible underpressure 40

Pipe identification mark 16

Pipe laying by milling 56

Pipe laying by ploughing 56

Pipeline trench 39

Pipe loading/unloading 51

Pipe string relining 56

PKS® 6

PKS® welding adapter 63

Plastic pipe production 10

Point load test according to Hessel 21

Polyethylene 5, 27, 28

Polyethylene, electrically conductive 28

Polypropylene 29

PRANDTL and COLEBROOK 36

Pre-delivery inspection 18

Preparation time for PKS® 61

Processing times for PKS sewage pipes

61

Properties of plastics 30

Push-fit connection 70

QQM system 25

Quality assurance 18

RRadiation resistance 27, 29

Regulation construction 76

Relining 56

Resistance to chemicals 28, 29

Resistance to high pressure cleaning

35

Road traffic loads 38

Roughness kb 36

SSafety classes 48

SAM 54

Secutec 9

Short pipe relining 56

Slightly cohesive soils 39

SN ring stiffness testing 20

Soakaways 77

Socket pressure tester 58, 63

Soil groups 39

Soil types 48

Special construction 77

Spiral pipe profile types

- PKS®plus 11

- PR 11

- PRO 11

- solid wall 11

- SQ 11

Spiral pipes 10

SR ring stiffness testing 20

Standards 87

Standard vehicles 38, 49

Static load

- explanations re. questionnaires 48,

49

- manhole data sheet 50

- static load questionnaire for man-

holes 46, 47

- static load questionnaire for sewage

pipe 44, 45

Storage

- DIN 8074/8075 extruded sewage

pipes 52

- DIN 16961 spiral pipes 52

Storm water construction 76

Storm water overflow 75

Storm water system 75, 76

Storm water tank 86

Strainer 75

Sureline® 8, 57, 85

TTangential manhole 74, 77

Temperature difference 42

Tensile stress in Sureline® pipe 57

Tensile test 19, 20

Tensile testing of weld 23

Testing conditions for gravity pipelines

according to DWA-A 139 58

Traceability code 17

Traffic load 38

Transport 51

Trench backfilling 48

Trench installation 38

- installation of PKS®/Profix pipes 53

- wall connection 54, 55

Trenchless installation

- burst lining 56

- drilling rocket 56

- hydraulic drilling method 56

- milling method 56

- pipe string relining 56

- ploughing method 56

- short pipe relining 56

- Sureline® 57

Trench zones 39

TSC-Pipe 7, 70

TÜV Rhineland certificate 25

Type PKS® 1 wall connection

- leakage test 55

UUltrasonic test 20

UV resistance 27, 29

VVertical shuttering 49

WWall connection 54, 55

Welding extruder 64, 65

Welding method 60

- butt welding 67

- electrofusion welding

- extruded sewage pipe 65, 66

- profiled sewage pipes 61, 62, 63

- extrusion welding 64

Welding ring 62

Welding robot 64

Welding stud 71

Welding times for PKS® 61

Weld seam 64

YY-piece 77


FRANK. DER VORSPRUNG.

FRANK GmbH Starkenburgstraße 1 64546 Mörfelden-Walldorf T +49 6105 4085 - 0 F +49 6105 4085 - 249 E [email protected] www.frank-gmbh.de

Documents

Technical part about sewage pipe systems - FRANK GmbH · Technical part about sewage pipe systems. About this catalogue This catalogue provides an overview of the applications and